hot runners and mould components - vogel.de · 7 industry news | may 2011 | european tool &...

52
Technology DLC coatings make tools hard and smooth Case Studies Industry suppliers support customers‘ success 28 32 Volume XIII | Issue 4 | May 2011 | 11 www.etmm-online.com Hot Runners and Mould Components Interview Guntram Meusburger from Meusburger GmbH 16 4/2011

Upload: lamhuong

Post on 04-Jun-2018

217 views

Category:

Documents


5 download

TRANSCRIPT

TechnologyDLC coatings make tools hard and smooth

Case StudiesIndustry suppliers support customerslsquo success28 32

Volume XIII | Issue 4 | May 2011 | euro11 wwwetmm-onlinecom

Hot Runners and Mould Components

InterviewGuntram Meusburger from Meusburger GmbH 16

420

11

1313

13

13

13

$

amp1313(

)

13131313

SEE IT WORK AND ACCESS CATALOG PAGES AND CAD DATA AT WWWPROCOMPSCOMDEMO

I remember when most tool and mould makers would

not have been very likely to use digital media But those days have gone

Over the past decade we have seen a lot of changes in digitally delivered content and also in the way mould makers interface with the World Wide Web Irsquom not

talking about transferring design data or other soft-ware artifacts over the Internet or communicating via e-mail I mean that they use the Internet to find the information they need to stay up-to-date remain competitive and make money

ldquoKnowledge is powerrdquo as the saying goes and between print and digital media a wealth of knowl-edge is available today We are watching the commu-nications revolution as it happens and we at ETMM are excited about all the new opportunities we have for delivering necessary information Here in Europe print media is still dominant in information delivery However as digital technology comes to play a more and more important role the communication pro-cess grows ever more efficient

There are several ways for tool and mould mak-ers to use digital media They can visit suppliersrsquo websites of course Then there are Google Ping and Wikipedia for gathering general information For more-specific information about the tool and mould making industry the choices are fewer but the ETMM family of digital products gives our read-ers an on-line platform they can count on This plat-form consists of the website (wwwetmm-onlinecom) a weekly e-newsletter and a monthly buyerrsquos guide update with a product newsletter

If you have not yet visited our website or signed up to get the weekly newsletter or monthly buyerrsquos guide update please go to wwwetmm-onlinecom to see for yourself what is available on-line

Digital Media and Mould Making CUTTING TOOL COMPANY

JAPANrsquoS NOCUTTING TOOL COMPANYUUTT IINGG TOOOOLL CCOOMMPPAANNYY

Mitsubishi House Galena CloseTamworth Staffs B77 4AS Tel + 44 (0) 1827 312312E-Mail salesmitsubishicarbidecoukwwwmitsubishicarbidecom

ANTI VIBRATIONEND MILLS

New generation for higher feed rates and greater depths of cutIMPACT MIRACLE coating for the ultimate in hard material millingVibration control geometry for a stable smooth cutting actionAvailable in a wide range of geometries and sizes Oslash2 - Oslash20mm

VF SERIES

Douglas SellersMANAGING DIRECTOREDITOR-IN-CHIEF

Editorrsquos Message

4

Table of Contents

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Interview 16Concentrating on Strengths a Mould Industry Supplier Grows

Product Focus 18Recently introduced products from suppliers of tool and mould components and hot runner technology

Quick Sourcing Grid Tool amp Mould Components 22A handy table of companies supplying components to the tool and mould making industry cross-indexed by more than 40 categories

Quick Sourcing Grid Hot Runner Systems and Components 26A handy table of companies supplying hot runner technology to the tool and mould making industry

COVER STORY

Editorrsquos Message 3As digital communication tools such as those ETMM offers appear and develop tool and mould makers stand to benefit

Industry News 7Corporate professional and educational events that define the direction of the industry

Technology28Hydrogen-Free DLC Coatings Make Tools Hard and Smooth

Technology30New Geometries Make Revised Drilling System More Efficient

Cover photo provided byMeusburger Georg GmbH amp Co KGKesselstraszlige 426960 Wolfurt AustriaTel +43 5574 67060Fax +43 5574 670611wwwmeusburgercom

Case Study 32PPS Software Ups Production Transparency for Mould Maker

Case Study 34Using a Powerful Yet Sensitive Tryout Press to Finish the Job

Case Study 36Forging Company Makes Dies from Tough Hard Tool Steel

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Tuumlrk+Hillinger GmbH78532 Tuttlingen Germany

Tel +49 74 61 70 140 Fax +49 74 61 70 1410

infotuerk-hillingerde

wwwtuerk-hillingerde

since 1963

we are your best choice forheating elements

wide product range

large repertory of stock types

customer-specific executions

modern rational manufacturing methods

over 30000 heating elements daily

certified according to DIN ISO 90012000

high life span

500 qualified employees

over 240 patent applications

made in Germany

June 2011The focus of the Cover Story in the next issue of ETMM is Machining Equipment This section will include an overview article short Product Focus articles and a Quick Sourcing Grid of equipment suppliers serving the tool and mould making industry

The June issue also offers bull A Special Report focusing on mould making in Russia and a

EuroMold perspective on the RosMould exhibitionbull A Technology section focus on cutting tools and machining

accessories for tool and mould makersbull The Summer 2011 issue of EDM Europe

NEXT ISSUE

Volume XIII | Issue 4 | May 2011

Case Study 38Compact 3D Printer Expands Development Firmrsquos Horizons

Products amp Services 40Recently introduced equipment and services from all over

ISTMA 49Directory of ISTMA Europe Member Associations

Company Index 50A listing of the industry suppliers who supported this issue with articles and advertisements

TRU

MPF

GRO

UP

Table of Contents

VOLUME XIII NUMBER 4 MAY 2011

EUROPEAN TOOL amp MOULD MAKINGPublished by SellersMedia

P U B L I S H E R E D I T O R - I N - C H I E F

Douglas Sellersdsellerssellersmediacom

SELLERSMEDIAOtto-von-Guericke-Ring 3A 65205 Wiesbaden Germany

Tel +49 6122 95590 bull Fax +49 6122 51090infoetmm-onlinecomwwwetmm-onlinecom

P R O D U C T I O N C I R C U L AT I O N amp I N F O R M AT I O N S E R V I C E S

Briggette Jayabjayasellersmediacom

Melanie Rosselmrosselsellersmediacom

G R A P H I C D E S I G N E R S

Jason Sellersjsellerssellersmediacom

Law Wai Manlwmsellersmediacom

I N F O R M AT I O N T E C H N O L O G Y S P E C I A L I S T

Markus Muumlllermmuellersellersmediacom

S A L E S M A N A G E R

Britta Sollowaybsollowaysellersmediacom

A D V E R T I S I N G S A L E S F R A N C E

Evelyne Gisselbrecht33 Rue du Puy-de-Docircme 63370 Lempdes France

Tel +33 473 619557 bull Fax +33 473 619661egisselbrechtsellersmediacom

R E P R E S E N TAT I V E A G E N T F O R TA I WA N C H I N A amp H O N G KO N G

Robert Yu Worldwide Services Co Ltd11F-B No 540 Wen Hsin Road Section 1 Taichung 408 Taiwan

Tel +886 4 23251784 bull Fax +886 4 23252967saleswwstaiwancom

N O R T H A M E R I C A N O F F I C E30765 Pacific Coast Highway PMB 351

Malibu CA 90265-3643 USATel +1 805 744-7924 bull Fax +1 310 507-2032

usofficetool-moldmakingcom

B U S I N E S S M A N A G E R

MiSook Musselmanmmusselmantool-moldmakingcom

EDITORIAL CONTRIBUTIONS Productservice information bulletins and press releases should be submitted in English and should be accompanied by a colour photograph or transparency The publishers assume no responsibility for return of artwork photographs or manuscripts NOTICE Every precaution is taken to ensure accuracy of contents however the publishers cannot accept responsibility for the correctness of the information supplied or advertised or for any opinion expressed herein

SUBSCRIPTIONS European Tool amp Mould Making is published 10 times per year

Annual subscription in Europe euro 7900 incl VAT (1 year) euro 15000 incl VAT (2 years)Readers outside Europe euro 9900 incl VAT (1 year) euro 18500 incl VAT (2 years)

Single copies euro 1100 incl VAT

Subscription inquiries back issues address changes send your request to European Tool amp Mould Makingby e-mail to etmmtool-moldmakingcom or by fax to +49 6122 51090

Circulation Audit Member of the Informationsgemeinschaft zur Feststellung der Verbreitung von Werbetraumlgern eV (IVW) Berlin

Printed at Koumlssinger AG wwwkoessingerde

Copyright copy 2011 ACCESS COMMUNICATIONS INC ALL RIGHTS RESERVED

OfficialMedia Partner of

ISTMA Europe

7

Industry News

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

More visitors an even more interna-tional character and the best pos-sible accompanying programme of events elucidating current industry trends are the objectives of the orga-nizer and sponsors of AMB 2012 the International Exhibition for Metal-working Messe Stuttgart along with the Precision Tools Association of the VDMA (German Engineering Federa-tion) the VDMA Software Association and the VDW (German Machine Tool Buildersrsquo Association) want the show

handling apparatus Nearly a quar-ter of the exhibiting companies last year came from a record 80 coun-tries outside Germany and the pro-portion of foreign visitors increased between 2008 and 2010 from 7 to 11 Messe Stuttgart is focusing on increasing the eventrsquos international-ization further in 2012

Organizer of AMB 2012 Building on Success

raquo AMB 2012Stuttgart Germanywwwmesse-stuttgartde

which takes place September 18ndash22 in Stuttgart to surpass the signal suc-cess of the 2010 edition which fully satisfied the more than 1300 exhibi-tors and 86000 visitors

Fully booked halls are expected again in 2012 with the exhibition occupying an area of 105000 m2 Exhibitors will be displaying main-ly milling machines lathes cutting tools chucking tools CADCAMCAE and other software grinding machines and workpiece- and tool-

RosMould 2011 Comes to Moscow in June

RosMould 2011 the special-ized international exhibition for moulds die moulds and stamps taking place June 15ndash17 at the Crocus Expo in Moscow is as the organizer Expo-M-Group Ltd says the only such trade fair offered within the post-Soviet Russian ter-ritory The show has relevance for all manufacturing sectors

Also notes Expo-M-Group the global economic crisis is becom-ing less of a factor in the field of moulds dies and stamps as pro-duction picks up in Russia and elsewhere Investors in produc-tion equipment are ready again to spend on the sort of technological advances in design and engineer-ing simulation and prototyping production software tooling die moulds and stamps materials metalworking and forming equip-ment automation and QC sys-tems and standard components RosMould exhibitors present

RosMould 2011 is co-located with RosPlast the specialized exhibition for plastics technology and products

raquo RosMould 2011Moscow Russiawwwrosmouldcom

Watch Mastercam circle the globe at wwwtinyurlcommcglobe

8

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

With more than 15000 installed seats of its CAM software world-wide and a global network of more than 120 resellers in 50 countries SolidCAM GmbH has enjoyed great success The companyrsquos biggest mar-ket is Germany where some 2000 users are working

The CAM Competence Centre of

Husky Injection Molding Systems is expected to complete its acquisition of KTW a global manufacturer of clo-sure moulds that is headquartered in Waidhofen Austria in May 2011 The purchase represents a logical next step in a 14-year relationship between the companies

Husky and KTW have worked together to develop closure manu-facturing systems that enhance cus-tomersrsquo productivity while eliminat-ing waste and improving part quality explains John Galt Husky president and CEO But even closer collaboration was seen to be necessary for meeting

DPS Software GmbH has contributed nicely to this success in Germany as was acknowledged during a recent ceremony at SolidCAM headquarters in Schramberg There Stephan Ter-horst the software developerrsquos Ger-man marketing director presented the award for most successful world-wide SolidCAM reseller in 2010 to Joumlrg

Rudig (at right in photo) the manager of the DPS CAM Competence Centre and his staff of 13

DPS Software has 13 subsidiaries and 145 employees making it one of the biggest product lifecycle manage-ment project partners in Germany Austria and Switzerland An important growth engine for the companyrsquos prow-ess in integrated CAD CAE CAM PDM and ERP software solutions and related services is its CAM Compe-tence Centre Since the time the cen-tre was founded in 2000 the com-petence centre team has provided an integrated SolidWorksSolidCAM CADCAM solution for more than 1500 CNC machines As Joumlrg Rudig points out a key part of DPSrsquos service offering is the provision of customer-oriented training programmes to sup-port its CADCAM products

increasingly high expectations partic-ularly in developing the core elements of closure systems

Husky will offer KTW-branded clo-sure moulds as part of its line of fully integrated turnkey systems when the deal is concluded making it the clo-sure industryrsquos only provider of com-plete injection moulding systems including the mould machine hot runner and temperature controller as well as consulting and after-sales ser-vices KTW managing directors Anja and Claus Ziegler will continue to be involved at the top management level

KTW operations in Austria the Czech Republic and Germany are to become Huskyrsquos closure mould devel-opment and manufacturing cen-tres of excellence In addition Husky plans to initiate a strategic review of KTWrsquos custom injection mould-ing division Injectoplast in order to ensure the divisionrsquos future success and avoid potential conflicts of inter-est with its own customers

SolidCAM Presents DPS Software with Global Best Reseller Award for 2010

raquo SolidCAM GmbHSchramberg Germanywwwsolidcamde

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Husky Solidifies Its Position in Closure-Mould Market through Acquisition of KTW

Molded to your needs

www3dscommoldandtooling

Mold amp ToolingBoost your efficiency and save time with a robust and innovative approach

CATIA Mold amp Tooling brings the extra added value of an integrated end-to-end solution From design and engineering to simulation and manufacturing take advantage of proven

optimized processes to satisfy the increasing expectations of your customers

ww

w3

dsc

om

copy

Das

saul

t Sy

stegravem

es 2

011

ndash A

ll ri

ghts

rese

rved

ndash C

ATI

A is

a re

gist

ered

tra

dem

ark

of D

assa

ult

Syst

egravemes

or

its

subs

idia

ries

in t

he U

S an

d

or o

ther

cou

ntri

es

10

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Industry News

New President for Sandvik Materials Technology

Mastercam for SolidWorks Wins Gold Partner Status

Peter Gossas president of Sandvik Materials Tech-nology for nine years will retire and leave the Sand-vik Group on May 31 2011 Jonas Gustavsson (pictured) currently president of the Wire and Heating Technol-ogy product area within Sandvik Materials Technol-ogy has been appointed as the business divisionrsquos new president He also becomes

a member of Sandvikrsquos group executive managementSandvik Materials Technology is the Sandvik business

area that supplies metalworking materials It occupies a position within the group equivalent to that of Sandvik Coromant the cutting-tools division

Gustavsson who earned a degree in mechanical engi-neering from Lulearing Technical University has acquired solid industry experience by holding senior positions within and outside Sandvik Says Olof Faxander president and CEO of Sandvik AB ldquoWith his broad background and proven ability

The Mastercam for SolidWorksreg software package developed by CNC Software Inc to support Solid-Worksreg 3D CAD software has been awarded Certified Gold Partner status by Dassault Systegravemes SolidWorks Corp Designers engineers and machinists use Mas-tercam for SolidWorks software to programme tool paths after designs have been finished in SolidWorks The tool paths are applied directly to the SolidWorks model in their native environment Thus users of Mastercam for SolidWorks and SolidWorks 2011 in combination can employ Mastercamreg CAM technolo-gy to create a machining programme without leaving the SolidWorks interface

ldquoWith our tool paths running directly in the Solid-Works environment our users will feel comfortable programming their parts just as if they were in stan-dard Mastercamrdquo explains CNC Software marketing manager Ben Mund ldquoThe beauty is that now they can run those tool paths inside of SolidWorks with-out the hassle of exporting files and handling the translationrdquo

The point of the cooperation as Nick Iwaskow SolidWorksrsquo manager of alliances points out is that ldquointegration between key product design applica-tions can shave precious time off of the develop-ment process and increase productivityrdquo Ultimately designers and engineers can improve their designs

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

raquo CNC Software IncTolland CT USAwwwmastercamcom

STRACK NORMAGmbH amp Co KGKoumlnigsberger Str 11D-58511 Luumldenscheid

Tailor - MadeSolutions

NEW

CENTRING ELEMENTSfree of play bull wear-free bull with needle rollers

Tel +49 (0) 2351 8701-0Fax +49 (0) 2351 8701-100wwwstrackdeinfostrackde

to successfully drive change Jonas Gustavsson has the right profile to lead Sandvik Materials Technologyrdquo

Faxander also acknowledges the achievements of Gos-sas noting that the outgoing president could take credit for moving the product programme increasingly toward high-value-added products improving manufacturing pro-cesses and stepping up product development

11

Industry News

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

phone +49 (0) 92529993-0

fax +49 (0) 92529993-33

vertriebrainer-knarrde

wwwrainer-knarrde

Visit us

hall 4 booth D62

- shaft without bulge

- head underneath and

head diameter ground

- height of head 0-003

- suitable as contour pin

- high temperature resistance

- ability for coating and nitration

- wide range of dimensions

Contact UK and Ireland

Gunther UK Limited

phone 01474879774

infogunthercouk

Contact Czech Republic

wwwrsmplastcz

ISO 90012008

certified

Innovative waved

baffle profile

- shorter cycle times

- improved cooling-effect

- swirl of the medium

- prolongable up to 625mm

- temperature resistant 200degC max

Protected

system

Reduce cycle times with the new generation of

cooling deflection baffles

Ejectors - outline pins

hardened approx 53 HRC

With 78 manufacturers suppliers and service providers from the addi-tive technologies sector having con-firmed their participation as exhibi-tors at EuroMold 2011 the trade fair for mould making and tooling design and application development is extending its claim to be the most important European marketplace for this growing industrial field also known as e-production Numerous market-leading innovators specializ-ing in additive manufacturing will be presenting themselves at the Frank-furt Exhibition Centre November 29 through December 2 particularly in Hall 11

The EuroMold organizer DEMAT GmbH has provided additional show-cases for the additive technologies sector through its offer of the uni-

versity researchndashbased special-focus show within a show ldquoe-Production for Everyonerdquo this year in its third edi-tion and the globally renowned Inter-national Wohlers Conference In 2011 the 13th Wohlers Conference will feature an emphasis on design in the production of additives

E-production experts think 2011 will be a year of strong growth driven by the release of pent-up demand for new product development technol-

ogies and services ldquoAs companies investigate additive manufacturing for the production of end-use prod-ucts a new level of technology adop-tion will unfoldrdquo says Terry Wohlers CEO of Wohlers Associates Inc

EuroMold 2011 presents the entire spectrum of additive technologies and their uses including 3D-printed products for industrial applications Among the top global companies dis-playing their latest materials tech-nologies and applications will be 3D Systems Alphacam Concept Laser EOS FIT Huntsman Materialise MTT Objet Realizer SLM Solutions Strata-sys and Z Corp

EuroMold 2011 Is Planned to Solidify Position As Premiere Additive Technologies Marketplace

raquo EuroMold 2011FrankfurtMain Germanywwweuromoldcom

EURO

MO

LD

12

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

In Sosnowiec Poland prepara-tions are in full swing for Toolex 2011 the International Machine Tools Tools and Processing Tech-nology Fair which is scheduled to take place October 5ndash7 at the Expo Silesia Exhibition Cen-tre This prestigious event for the metal-processing industry attracts more and more indus-try experts every year In 2010 more than 6000 professional and expert show visitors were very satisfied by what they found at the 167 exhibition stands showcasing over 350 companies from more than two dozen coun-tries around the world

Toolex always offers a compre-hensive presentation of machine tools specialized tools tech-nological equipment software and measuring and control instruments including world premieres of many machines and tools Last year in an exhibition area extending over more than 4000 m2 181 metal-processing machine tools on display were in full operation The venue is equipped to allow exhibitors to display large and

complex operating machines includ-ing entire assembly lines

The exhibition facility in Sosno wiec is situated in the heart of Polandrsquos most industrial region which is also an important scientific centre The area of Silesia and Zaglebie is home to a range of fast-growing industri-al sectors such as the automotive

aviation and mechanical engineer-ing industries among others Also the Czech Republic and Slovakia are nearby Transportation access to the venue is well developed

Expo Silesia Expects Toolex 2011 to Be Another Successful Metal-Processing Fair

raquo Toolex 2011Sosnowiec Polandwwwtoolexpl

MCH Swiss Exhibition (Basel) Ltd has handed over the organization and operation of Swisstech Europersquos Central Fair for the Subcontracting Industries to its wholly owned sub-sidiary Exhibit amp More AG The latter company now is in charge of Swiss-tech 2012 scheduled for November 20ndash23 2012 in Basel Exhibit amp More headquartered near Zuumlrich has been organizing specialist industrial fairs for more than 30 years

Swisstech is a key meeting point

The MCH Group assumed full con-trol of Exhibit amp More at the beginning of 2010 The managers of both trade fair organizing entities are convinced that the merger of their forces will make it possible to position Swisstech and Prodex in the market more effi-ciently and to steer a course toward a successful future

Swisstech Fair Henceforward in Hands of MCH Messe Basel Subsidiary Exhibit amp More

raquo Exhibit amp More AGFaumlllanden-Zuumlrich Switzerlandwwwexhibitandmorech

every two years for the subcontract-ing industry companies operating in the fields of procurement manu-facturing and production technolo-gy MCHmdashalso known as MCH Messe Baselmdashhas used Swisstech to high-light the synergies that exist between the mechanical engineering industry and the world of specialist suppliers It has also organized Prodex the spe-cialist exhibition for machine tools tools and production measurement in parallel with Swisstech since 2004

Who knocks PET bottles into shape

CorroPlastreg

ndash the ultimate steel forall-stainless mould sets

DEUTSCHE EDELSTAHLWERKE Obere Kaiserstr D-57078 Siegen Auestr 4 D-58452 Witten

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Industry News

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

Interactive Meusburger Catalogue Provides Free Standard Parts Calculation

Version 50 of the interactive CD catalogue issued by Meusburger the Austrian manufacturer of standard parts has many new features The catalogue software includes new products for mould making as well as the entire punching tool product range a recent addition to the Meusburger portfolio The company has prided itself on setting industry trends for digital catalogues and the advanced features in the latest CD version continue the customer-oriented tradition

The software is equipped with a mould assistant for injection moulding tools and a die-set assistant for punch-ing-tool construction Selecting various plates from a mod-ular system users can assemble mould tools and die sets with just a few clicks of the mouse The software then cal-culates all necessary accessories fully automatically and free of charge The CD catalogue includes 3D models of more than 46000 Meusburger products which are easily exported into all current CAD systems and as neutral data

By displaying individual prices for different customers the digital catalogue renders inquiries obsolete Also the integrated e-mail function makes ordering a faster and simpler process Useful search options and new group fil-ters (with pictures) help save time and effort in looking for products And finally an automatic update feature makes sure that users are working with the latest software and will not miss any newly introduced products

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo FIP Solution Plastique 2011Lyon Francewwwf-i-pcom

raquo Eberhard WerkzeugtechnologieNordheim Germanywwweberhardde

FIP 2011 Plastics Industry Exhibition Due in Lyon in May

Eberhard GmbH Enjoys a 28 Increase in Turnover in 2010

From May 24 to 27 the Rhocircne capital of Lyon will host FIP Solution Plastique 2011 the Plastics Industry Exhibition in France FIP is the only French trade show that brings all of the plastics industry players togeth-er in one place in this case the Lyon Eurexpo More than 500 exhibitors representing all aspects of the plas-tics industry will be on hand These include upstream suppliers of raw materials as well as producers or pro-viders of machines and equipment moulds and tools design services prototypes and models inspection technologies for quality control soft-ware and recycling technology Pro-cessors directly connected with final clients will be present in the area des-ignated FIPrsquoProjets

Because innovation is so important for companies wishing to stand out in

Gebruumlder Eberhard GmbH the par-ent company of the tool technology specialist Eberhard Werkzeugtech-nologie increased its turnover to just under euro90 million in 2010 a 28 rise Thus the company has managed to top the highest figure it had achieved before the period of economic crisis Meanwhile its staff increased by 10 last year to 440 employees

Eberhard GmbH manufactures stan-dard parts and accessories for tools in Nordheim and runs a specialized electrical retail outlet in Heilbronn as well as operating an additional tool technology production site in Thuringia and another electrical retail outlet in Saxony

Z 107101 Z 107105

The new universalneedle valvepermits the construction of compactmoulds and simplifies the integration of the needle valve systems in manyapplications

Unique flexibility in nozzle length and diameter

Can be used with all standard nozzles

Flexible valve pin strokeup to 7 mm

Available for 2 needle diameters (2 and 25 mm)

Flexible drive solutions Hydraulic internal or pneumatic external

No melt split in the diverting unit

Integration in stack and tandem moulds is possible

Minimum mounting space

HASCO Hasenclever GmbH+Co KGIm Wiesental 77 middot D-58513 LuumldenscheidTel +49 2351 957-0 middot Fax +49 2351 957-237E-mail infohascocom middot wwwhascocom

Together we shape your ideas

Improved colour change properties

the market FIP Solu-tion Plastique 2011 includes the Innova-tion Forum which offers a harmonized overview of recent industry develop-

ments Exhibitors in 15- to 20-minute speeches will unveil innovative solu-tions that resulted from advanced research and new technologies The trade fair also comprises a free con-ference programme and other edu-cational offerings to complement the Innovation Forum and FIPrsquoProjets

The 4th annual Caoutchouc Caucho Gomma international meeting of the rubber and polymer industries takes place at the same time as FIP Solution Plastique 2011 and also in the Lyon Eurexpo

The company benefited from the fact that it did not reduce its work-force in 2009 despite a significant decline in turnover In fact it made extensive investments and doubled the production area in Nordheim ldquoAfter all positive continuity is what sets down-to-earth family-owned companies apartrdquo says CEO Roland Eberhard Eberhard GmbH also expanded its vocational trainee pro-gramme and has signed contracts with a second generation of students at the Cooperative University

Industry News

16

Cover Story | Interview

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

A company with a strong pres-ence in Europe Meusburger

is a long-established specialist in the field of standard moulds In the past few years the Austrian enterprise has invested consider-able resources in expanding plant capacity in an effort to keep pace with its business growth Mean-while it introduced a completely new line of tool components to

enlarge an already bulging product catalogue

A strong position in the Euro-pean market is not alone enough for Meusburger Standard Moulds however The company founded a sales office in China in 2010 ETMM spoke with the companyrsquos managing director Guntram Meusburger son of the epony-mous founder about these and other aspects of Meusburgerrsquos present and future operations

ETMM Please give us a brief history of Meusburger GmbH How did the company start and how did it reach its present statureMeusburger ldquoConcentrating on our own strengthsrdquomdashthis slogan has been guiding Meusburger ever since 1964 The company started off as a one-man business and today employs 420 members of staff By continuously focusing on its own strengths clearly struc-tured processes the targeting of products to meet customer needs

and quality assurance Meusburg-er has become a European leader in the field of standard moulds which represents the companyrsquos main product line

Which industry sector is most impor-tant to your company and which sectors are you looking to develop furtherMeusburger stands for continu-ity and growthmdashand especially for high-quality products for the tool and mould making industry Last year we created space for some new things and we became very active in many other areas as well For example we prepared the introduction of a new field of businessmdashnamely punching tool

construction for which we have developed products We want to continue on this successful path in the coming year

We are particularly proud of our modular systemndashbased punch-ing-tool standard parts which are completely new However though these products are in fact new we have managed to adapt numerous well-known Meusburger advan-tages from our injection-mould-making range for use in construct-ing the punching tools

What recent or forthcoming new tech-nologies will bring your customers more value in the futureStress-relieved standard parts that is the obvious answer Playing a key role at the beginning of the process chain these components form a reliable foundation for high-quality moulds and tools The latest investment project of Meusburger has been additional furnaces with 120 tons of loading capacity per day With this invest-ment we increased the existing capacity by more than half

Stress-relieved standard parts in particular the parts for injec-tion moulds and punching dies offer many benefits to toolmak-ers We apply the stress-relieving

Concentrating on Strengths a Mould Industry Supplier GrowsMeusburger Standard Moulds has been successful for nearly half a century and its director suggests intends not to let up

ldquoMeusburger stands for continuity and growthmdashand especially for high-quality products for the tool and mould making industry We place great value on products that provide a clear added value for our customersrdquo

Managing Director Guntram Meusburger

wwwthebrightworldofmetalscom wwwgmtnde

One date ndash one place ndash four eventsMake the most of four high-calibre trade fairs ndash for foundry technology metallurgy thermo process technology and precision castings ndash in one place and with one entrance ticket

The industriesrsquo Number 1 worldwide multiple synergies connections and networks all in just one show visit Welcome to Duumlsseldorf

The Bright Worldof MetalsDuumlsseldorf Germany 28 June ndash 02 July 2011

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Interview

heat treatment to all grades of steel That is the best prerequisite for warp-free machining of parts

What do you consider to be Meusburgerrsquos most important product rangeManufacturing plates for injection moulding and punching tools clearly is our biggest strength in rela-tion to our competitors Meusburger uses the best raw materials and suppliers and we implement a programme of complete quality assurance through-out the production process

How important is research and development to Meus-burger Standard MouldsWe place great value on products that provide a clear added value for our customers Therefore we develop new products by working together with customers to fulfill not only their specific needs but also and especially the needs of the market generally

Is Meusburger GmbH active in AsiaIn 2010 we opened a new sales office in Wuxi China in Jiangsu Province The reason for that is that many of our customers have manufacturing operations in China and have expressed an inter-est in using standard products made by Meusburger there As a supplier of high-quality standard parts we naturally thought it was important for us to have an in-country sales office of our own

Incidentally from May 17 to May 20 this year Meusburger GmbH will be represented for the first time at the Chinaplas trade fair which is being held in the city of Guangzhou China We invite read-ers intending to visit that show to come see us at Stand D 41 in Hall 32

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

The investment of millions of euros in the Meusburger production facility in Wolfurt in recent years extended the companyrsquos capabilities For example new furnaces allow the standard parts manufacturer to produce stress-relieved components in greater volume

18

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Advanced series of customized hot runner systems a thoroughly innovative new solution

from DME has been designed to free mould makers from the limita-tions imposed by ldquohalf-

standardrdquo solutionsmdashthat is the use of standard

products to construct a special hot runner system

With the concept-products of the Advanced series the

moulder receives a fully cus-tomer-specific system tailored

to defined needs without any compromising that will perform

exactly as it should

This hot runner series was made possible by the development of sev-eral different nozzle tips with new openings These provide an opti-mal solution for every material and accommodate lateral-injection and multiple-gating requirements Within 24 hours of request DME will offer a quotation for a complex hot runner solution including a 3D drawing and a multiflow system if needed Deliv-ery of such a system can be expect-ed in 7 to 20 working days depend-ing on the complexity plus transport Expedited delivery also is available

raquo DME EuropeMechelen Belgiumwwwdmeeucom

Custom Hot Runners without Compromise Are Available via New System Solution

Rainer Knarr Vertriebs GmbH spe-cializes in the manufacture and sup-ply of standard and custom mould parts The company prides itself on including in its standards line mould accessories that other suppliers might offer only as specials

Beyond its extensive range of stan-dard components Rainer Knarr also provides custom mould components for tool and mould makers and injec-tion-moulders such as flat ejector pins with corner radius flat ejector pins with an extralong blade step-less sleeve ejectors pins that have a diamondlike-carbon (DLC) coating (photo) ejectors with an antitwist lock and many others All of these so-called standardized specials come in a wide range of stocked dimensions

The Rainer Knarr Group operates its own mould making division There-fore it well understands the needs and challenges of mould makers and

injection moulders The supplier sup-ports customers by offering a flexible ordering and deliv-ery servicemdashwith same-day shipping even for emergency orders received on Saturdaymdashan on-line shop and CAD data that is available for downloading

Always working on developing better solutions Rainer Knarr has recently launched several new product lines One is the huge XXL programme of flat ejector pins This line features pins in dimensions other than the well-known standard ones In addition it includes flat ejec-tors with corner radii and a DLC coat-ing flat ejectors with a long sheet and high-speed flat ejectors

Another line con-sists of patented hardened or nitrid-ed stepless ejector sleeves designed to facilitate reduction of the guide length

Also new from Rainer Knarr is a range of waved deflection baffles made of plastic which help ensure efficient balanced

mould cooling And the last highlight-ed recent introduction from the com-pany is a series of ejectors for outline pins that are made of hot-working steel hardened to 53 HRc for opti-mum machinability

Service-Oriented Supplier Provides Standard Mould Parts and Standardized Specials

raquo Rainer Knarr Vertriebs GmbHHelmbrechts Germanywwwrainer-knarrde

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

1313

13

13

13

$

amp1313(

)

13131313

SEE IT WORK AND ACCESS CATALOG PAGES AND CAD DATA AT WWWPROCOMPSCOMDEMO

I remember when most tool and mould makers would

not have been very likely to use digital media But those days have gone

Over the past decade we have seen a lot of changes in digitally delivered content and also in the way mould makers interface with the World Wide Web Irsquom not

talking about transferring design data or other soft-ware artifacts over the Internet or communicating via e-mail I mean that they use the Internet to find the information they need to stay up-to-date remain competitive and make money

ldquoKnowledge is powerrdquo as the saying goes and between print and digital media a wealth of knowl-edge is available today We are watching the commu-nications revolution as it happens and we at ETMM are excited about all the new opportunities we have for delivering necessary information Here in Europe print media is still dominant in information delivery However as digital technology comes to play a more and more important role the communication pro-cess grows ever more efficient

There are several ways for tool and mould mak-ers to use digital media They can visit suppliersrsquo websites of course Then there are Google Ping and Wikipedia for gathering general information For more-specific information about the tool and mould making industry the choices are fewer but the ETMM family of digital products gives our read-ers an on-line platform they can count on This plat-form consists of the website (wwwetmm-onlinecom) a weekly e-newsletter and a monthly buyerrsquos guide update with a product newsletter

If you have not yet visited our website or signed up to get the weekly newsletter or monthly buyerrsquos guide update please go to wwwetmm-onlinecom to see for yourself what is available on-line

Digital Media and Mould Making CUTTING TOOL COMPANY

JAPANrsquoS NOCUTTING TOOL COMPANYUUTT IINGG TOOOOLL CCOOMMPPAANNYY

Mitsubishi House Galena CloseTamworth Staffs B77 4AS Tel + 44 (0) 1827 312312E-Mail salesmitsubishicarbidecoukwwwmitsubishicarbidecom

ANTI VIBRATIONEND MILLS

New generation for higher feed rates and greater depths of cutIMPACT MIRACLE coating for the ultimate in hard material millingVibration control geometry for a stable smooth cutting actionAvailable in a wide range of geometries and sizes Oslash2 - Oslash20mm

VF SERIES

Douglas SellersMANAGING DIRECTOREDITOR-IN-CHIEF

Editorrsquos Message

4

Table of Contents

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Interview 16Concentrating on Strengths a Mould Industry Supplier Grows

Product Focus 18Recently introduced products from suppliers of tool and mould components and hot runner technology

Quick Sourcing Grid Tool amp Mould Components 22A handy table of companies supplying components to the tool and mould making industry cross-indexed by more than 40 categories

Quick Sourcing Grid Hot Runner Systems and Components 26A handy table of companies supplying hot runner technology to the tool and mould making industry

COVER STORY

Editorrsquos Message 3As digital communication tools such as those ETMM offers appear and develop tool and mould makers stand to benefit

Industry News 7Corporate professional and educational events that define the direction of the industry

Technology28Hydrogen-Free DLC Coatings Make Tools Hard and Smooth

Technology30New Geometries Make Revised Drilling System More Efficient

Cover photo provided byMeusburger Georg GmbH amp Co KGKesselstraszlige 426960 Wolfurt AustriaTel +43 5574 67060Fax +43 5574 670611wwwmeusburgercom

Case Study 32PPS Software Ups Production Transparency for Mould Maker

Case Study 34Using a Powerful Yet Sensitive Tryout Press to Finish the Job

Case Study 36Forging Company Makes Dies from Tough Hard Tool Steel

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Tuumlrk+Hillinger GmbH78532 Tuttlingen Germany

Tel +49 74 61 70 140 Fax +49 74 61 70 1410

infotuerk-hillingerde

wwwtuerk-hillingerde

since 1963

we are your best choice forheating elements

wide product range

large repertory of stock types

customer-specific executions

modern rational manufacturing methods

over 30000 heating elements daily

certified according to DIN ISO 90012000

high life span

500 qualified employees

over 240 patent applications

made in Germany

June 2011The focus of the Cover Story in the next issue of ETMM is Machining Equipment This section will include an overview article short Product Focus articles and a Quick Sourcing Grid of equipment suppliers serving the tool and mould making industry

The June issue also offers bull A Special Report focusing on mould making in Russia and a

EuroMold perspective on the RosMould exhibitionbull A Technology section focus on cutting tools and machining

accessories for tool and mould makersbull The Summer 2011 issue of EDM Europe

NEXT ISSUE

Volume XIII | Issue 4 | May 2011

Case Study 38Compact 3D Printer Expands Development Firmrsquos Horizons

Products amp Services 40Recently introduced equipment and services from all over

ISTMA 49Directory of ISTMA Europe Member Associations

Company Index 50A listing of the industry suppliers who supported this issue with articles and advertisements

TRU

MPF

GRO

UP

Table of Contents

VOLUME XIII NUMBER 4 MAY 2011

EUROPEAN TOOL amp MOULD MAKINGPublished by SellersMedia

P U B L I S H E R E D I T O R - I N - C H I E F

Douglas Sellersdsellerssellersmediacom

SELLERSMEDIAOtto-von-Guericke-Ring 3A 65205 Wiesbaden Germany

Tel +49 6122 95590 bull Fax +49 6122 51090infoetmm-onlinecomwwwetmm-onlinecom

P R O D U C T I O N C I R C U L AT I O N amp I N F O R M AT I O N S E R V I C E S

Briggette Jayabjayasellersmediacom

Melanie Rosselmrosselsellersmediacom

G R A P H I C D E S I G N E R S

Jason Sellersjsellerssellersmediacom

Law Wai Manlwmsellersmediacom

I N F O R M AT I O N T E C H N O L O G Y S P E C I A L I S T

Markus Muumlllermmuellersellersmediacom

S A L E S M A N A G E R

Britta Sollowaybsollowaysellersmediacom

A D V E R T I S I N G S A L E S F R A N C E

Evelyne Gisselbrecht33 Rue du Puy-de-Docircme 63370 Lempdes France

Tel +33 473 619557 bull Fax +33 473 619661egisselbrechtsellersmediacom

R E P R E S E N TAT I V E A G E N T F O R TA I WA N C H I N A amp H O N G KO N G

Robert Yu Worldwide Services Co Ltd11F-B No 540 Wen Hsin Road Section 1 Taichung 408 Taiwan

Tel +886 4 23251784 bull Fax +886 4 23252967saleswwstaiwancom

N O R T H A M E R I C A N O F F I C E30765 Pacific Coast Highway PMB 351

Malibu CA 90265-3643 USATel +1 805 744-7924 bull Fax +1 310 507-2032

usofficetool-moldmakingcom

B U S I N E S S M A N A G E R

MiSook Musselmanmmusselmantool-moldmakingcom

EDITORIAL CONTRIBUTIONS Productservice information bulletins and press releases should be submitted in English and should be accompanied by a colour photograph or transparency The publishers assume no responsibility for return of artwork photographs or manuscripts NOTICE Every precaution is taken to ensure accuracy of contents however the publishers cannot accept responsibility for the correctness of the information supplied or advertised or for any opinion expressed herein

SUBSCRIPTIONS European Tool amp Mould Making is published 10 times per year

Annual subscription in Europe euro 7900 incl VAT (1 year) euro 15000 incl VAT (2 years)Readers outside Europe euro 9900 incl VAT (1 year) euro 18500 incl VAT (2 years)

Single copies euro 1100 incl VAT

Subscription inquiries back issues address changes send your request to European Tool amp Mould Makingby e-mail to etmmtool-moldmakingcom or by fax to +49 6122 51090

Circulation Audit Member of the Informationsgemeinschaft zur Feststellung der Verbreitung von Werbetraumlgern eV (IVW) Berlin

Printed at Koumlssinger AG wwwkoessingerde

Copyright copy 2011 ACCESS COMMUNICATIONS INC ALL RIGHTS RESERVED

OfficialMedia Partner of

ISTMA Europe

7

Industry News

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

More visitors an even more interna-tional character and the best pos-sible accompanying programme of events elucidating current industry trends are the objectives of the orga-nizer and sponsors of AMB 2012 the International Exhibition for Metal-working Messe Stuttgart along with the Precision Tools Association of the VDMA (German Engineering Federa-tion) the VDMA Software Association and the VDW (German Machine Tool Buildersrsquo Association) want the show

handling apparatus Nearly a quar-ter of the exhibiting companies last year came from a record 80 coun-tries outside Germany and the pro-portion of foreign visitors increased between 2008 and 2010 from 7 to 11 Messe Stuttgart is focusing on increasing the eventrsquos international-ization further in 2012

Organizer of AMB 2012 Building on Success

raquo AMB 2012Stuttgart Germanywwwmesse-stuttgartde

which takes place September 18ndash22 in Stuttgart to surpass the signal suc-cess of the 2010 edition which fully satisfied the more than 1300 exhibi-tors and 86000 visitors

Fully booked halls are expected again in 2012 with the exhibition occupying an area of 105000 m2 Exhibitors will be displaying main-ly milling machines lathes cutting tools chucking tools CADCAMCAE and other software grinding machines and workpiece- and tool-

RosMould 2011 Comes to Moscow in June

RosMould 2011 the special-ized international exhibition for moulds die moulds and stamps taking place June 15ndash17 at the Crocus Expo in Moscow is as the organizer Expo-M-Group Ltd says the only such trade fair offered within the post-Soviet Russian ter-ritory The show has relevance for all manufacturing sectors

Also notes Expo-M-Group the global economic crisis is becom-ing less of a factor in the field of moulds dies and stamps as pro-duction picks up in Russia and elsewhere Investors in produc-tion equipment are ready again to spend on the sort of technological advances in design and engineer-ing simulation and prototyping production software tooling die moulds and stamps materials metalworking and forming equip-ment automation and QC sys-tems and standard components RosMould exhibitors present

RosMould 2011 is co-located with RosPlast the specialized exhibition for plastics technology and products

raquo RosMould 2011Moscow Russiawwwrosmouldcom

Watch Mastercam circle the globe at wwwtinyurlcommcglobe

8

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

With more than 15000 installed seats of its CAM software world-wide and a global network of more than 120 resellers in 50 countries SolidCAM GmbH has enjoyed great success The companyrsquos biggest mar-ket is Germany where some 2000 users are working

The CAM Competence Centre of

Husky Injection Molding Systems is expected to complete its acquisition of KTW a global manufacturer of clo-sure moulds that is headquartered in Waidhofen Austria in May 2011 The purchase represents a logical next step in a 14-year relationship between the companies

Husky and KTW have worked together to develop closure manu-facturing systems that enhance cus-tomersrsquo productivity while eliminat-ing waste and improving part quality explains John Galt Husky president and CEO But even closer collaboration was seen to be necessary for meeting

DPS Software GmbH has contributed nicely to this success in Germany as was acknowledged during a recent ceremony at SolidCAM headquarters in Schramberg There Stephan Ter-horst the software developerrsquos Ger-man marketing director presented the award for most successful world-wide SolidCAM reseller in 2010 to Joumlrg

Rudig (at right in photo) the manager of the DPS CAM Competence Centre and his staff of 13

DPS Software has 13 subsidiaries and 145 employees making it one of the biggest product lifecycle manage-ment project partners in Germany Austria and Switzerland An important growth engine for the companyrsquos prow-ess in integrated CAD CAE CAM PDM and ERP software solutions and related services is its CAM Compe-tence Centre Since the time the cen-tre was founded in 2000 the com-petence centre team has provided an integrated SolidWorksSolidCAM CADCAM solution for more than 1500 CNC machines As Joumlrg Rudig points out a key part of DPSrsquos service offering is the provision of customer-oriented training programmes to sup-port its CADCAM products

increasingly high expectations partic-ularly in developing the core elements of closure systems

Husky will offer KTW-branded clo-sure moulds as part of its line of fully integrated turnkey systems when the deal is concluded making it the clo-sure industryrsquos only provider of com-plete injection moulding systems including the mould machine hot runner and temperature controller as well as consulting and after-sales ser-vices KTW managing directors Anja and Claus Ziegler will continue to be involved at the top management level

KTW operations in Austria the Czech Republic and Germany are to become Huskyrsquos closure mould devel-opment and manufacturing cen-tres of excellence In addition Husky plans to initiate a strategic review of KTWrsquos custom injection mould-ing division Injectoplast in order to ensure the divisionrsquos future success and avoid potential conflicts of inter-est with its own customers

SolidCAM Presents DPS Software with Global Best Reseller Award for 2010

raquo SolidCAM GmbHSchramberg Germanywwwsolidcamde

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Husky Solidifies Its Position in Closure-Mould Market through Acquisition of KTW

Molded to your needs

www3dscommoldandtooling

Mold amp ToolingBoost your efficiency and save time with a robust and innovative approach

CATIA Mold amp Tooling brings the extra added value of an integrated end-to-end solution From design and engineering to simulation and manufacturing take advantage of proven

optimized processes to satisfy the increasing expectations of your customers

ww

w3

dsc

om

copy

Das

saul

t Sy

stegravem

es 2

011

ndash A

ll ri

ghts

rese

rved

ndash C

ATI

A is

a re

gist

ered

tra

dem

ark

of D

assa

ult

Syst

egravemes

or

its

subs

idia

ries

in t

he U

S an

d

or o

ther

cou

ntri

es

10

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Industry News

New President for Sandvik Materials Technology

Mastercam for SolidWorks Wins Gold Partner Status

Peter Gossas president of Sandvik Materials Tech-nology for nine years will retire and leave the Sand-vik Group on May 31 2011 Jonas Gustavsson (pictured) currently president of the Wire and Heating Technol-ogy product area within Sandvik Materials Technol-ogy has been appointed as the business divisionrsquos new president He also becomes

a member of Sandvikrsquos group executive managementSandvik Materials Technology is the Sandvik business

area that supplies metalworking materials It occupies a position within the group equivalent to that of Sandvik Coromant the cutting-tools division

Gustavsson who earned a degree in mechanical engi-neering from Lulearing Technical University has acquired solid industry experience by holding senior positions within and outside Sandvik Says Olof Faxander president and CEO of Sandvik AB ldquoWith his broad background and proven ability

The Mastercam for SolidWorksreg software package developed by CNC Software Inc to support Solid-Worksreg 3D CAD software has been awarded Certified Gold Partner status by Dassault Systegravemes SolidWorks Corp Designers engineers and machinists use Mas-tercam for SolidWorks software to programme tool paths after designs have been finished in SolidWorks The tool paths are applied directly to the SolidWorks model in their native environment Thus users of Mastercam for SolidWorks and SolidWorks 2011 in combination can employ Mastercamreg CAM technolo-gy to create a machining programme without leaving the SolidWorks interface

ldquoWith our tool paths running directly in the Solid-Works environment our users will feel comfortable programming their parts just as if they were in stan-dard Mastercamrdquo explains CNC Software marketing manager Ben Mund ldquoThe beauty is that now they can run those tool paths inside of SolidWorks with-out the hassle of exporting files and handling the translationrdquo

The point of the cooperation as Nick Iwaskow SolidWorksrsquo manager of alliances points out is that ldquointegration between key product design applica-tions can shave precious time off of the develop-ment process and increase productivityrdquo Ultimately designers and engineers can improve their designs

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

raquo CNC Software IncTolland CT USAwwwmastercamcom

STRACK NORMAGmbH amp Co KGKoumlnigsberger Str 11D-58511 Luumldenscheid

Tailor - MadeSolutions

NEW

CENTRING ELEMENTSfree of play bull wear-free bull with needle rollers

Tel +49 (0) 2351 8701-0Fax +49 (0) 2351 8701-100wwwstrackdeinfostrackde

to successfully drive change Jonas Gustavsson has the right profile to lead Sandvik Materials Technologyrdquo

Faxander also acknowledges the achievements of Gos-sas noting that the outgoing president could take credit for moving the product programme increasingly toward high-value-added products improving manufacturing pro-cesses and stepping up product development

11

Industry News

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

phone +49 (0) 92529993-0

fax +49 (0) 92529993-33

vertriebrainer-knarrde

wwwrainer-knarrde

Visit us

hall 4 booth D62

- shaft without bulge

- head underneath and

head diameter ground

- height of head 0-003

- suitable as contour pin

- high temperature resistance

- ability for coating and nitration

- wide range of dimensions

Contact UK and Ireland

Gunther UK Limited

phone 01474879774

infogunthercouk

Contact Czech Republic

wwwrsmplastcz

ISO 90012008

certified

Innovative waved

baffle profile

- shorter cycle times

- improved cooling-effect

- swirl of the medium

- prolongable up to 625mm

- temperature resistant 200degC max

Protected

system

Reduce cycle times with the new generation of

cooling deflection baffles

Ejectors - outline pins

hardened approx 53 HRC

With 78 manufacturers suppliers and service providers from the addi-tive technologies sector having con-firmed their participation as exhibi-tors at EuroMold 2011 the trade fair for mould making and tooling design and application development is extending its claim to be the most important European marketplace for this growing industrial field also known as e-production Numerous market-leading innovators specializ-ing in additive manufacturing will be presenting themselves at the Frank-furt Exhibition Centre November 29 through December 2 particularly in Hall 11

The EuroMold organizer DEMAT GmbH has provided additional show-cases for the additive technologies sector through its offer of the uni-

versity researchndashbased special-focus show within a show ldquoe-Production for Everyonerdquo this year in its third edi-tion and the globally renowned Inter-national Wohlers Conference In 2011 the 13th Wohlers Conference will feature an emphasis on design in the production of additives

E-production experts think 2011 will be a year of strong growth driven by the release of pent-up demand for new product development technol-

ogies and services ldquoAs companies investigate additive manufacturing for the production of end-use prod-ucts a new level of technology adop-tion will unfoldrdquo says Terry Wohlers CEO of Wohlers Associates Inc

EuroMold 2011 presents the entire spectrum of additive technologies and their uses including 3D-printed products for industrial applications Among the top global companies dis-playing their latest materials tech-nologies and applications will be 3D Systems Alphacam Concept Laser EOS FIT Huntsman Materialise MTT Objet Realizer SLM Solutions Strata-sys and Z Corp

EuroMold 2011 Is Planned to Solidify Position As Premiere Additive Technologies Marketplace

raquo EuroMold 2011FrankfurtMain Germanywwweuromoldcom

EURO

MO

LD

12

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

In Sosnowiec Poland prepara-tions are in full swing for Toolex 2011 the International Machine Tools Tools and Processing Tech-nology Fair which is scheduled to take place October 5ndash7 at the Expo Silesia Exhibition Cen-tre This prestigious event for the metal-processing industry attracts more and more indus-try experts every year In 2010 more than 6000 professional and expert show visitors were very satisfied by what they found at the 167 exhibition stands showcasing over 350 companies from more than two dozen coun-tries around the world

Toolex always offers a compre-hensive presentation of machine tools specialized tools tech-nological equipment software and measuring and control instruments including world premieres of many machines and tools Last year in an exhibition area extending over more than 4000 m2 181 metal-processing machine tools on display were in full operation The venue is equipped to allow exhibitors to display large and

complex operating machines includ-ing entire assembly lines

The exhibition facility in Sosno wiec is situated in the heart of Polandrsquos most industrial region which is also an important scientific centre The area of Silesia and Zaglebie is home to a range of fast-growing industri-al sectors such as the automotive

aviation and mechanical engineer-ing industries among others Also the Czech Republic and Slovakia are nearby Transportation access to the venue is well developed

Expo Silesia Expects Toolex 2011 to Be Another Successful Metal-Processing Fair

raquo Toolex 2011Sosnowiec Polandwwwtoolexpl

MCH Swiss Exhibition (Basel) Ltd has handed over the organization and operation of Swisstech Europersquos Central Fair for the Subcontracting Industries to its wholly owned sub-sidiary Exhibit amp More AG The latter company now is in charge of Swiss-tech 2012 scheduled for November 20ndash23 2012 in Basel Exhibit amp More headquartered near Zuumlrich has been organizing specialist industrial fairs for more than 30 years

Swisstech is a key meeting point

The MCH Group assumed full con-trol of Exhibit amp More at the beginning of 2010 The managers of both trade fair organizing entities are convinced that the merger of their forces will make it possible to position Swisstech and Prodex in the market more effi-ciently and to steer a course toward a successful future

Swisstech Fair Henceforward in Hands of MCH Messe Basel Subsidiary Exhibit amp More

raquo Exhibit amp More AGFaumlllanden-Zuumlrich Switzerlandwwwexhibitandmorech

every two years for the subcontract-ing industry companies operating in the fields of procurement manu-facturing and production technolo-gy MCHmdashalso known as MCH Messe Baselmdashhas used Swisstech to high-light the synergies that exist between the mechanical engineering industry and the world of specialist suppliers It has also organized Prodex the spe-cialist exhibition for machine tools tools and production measurement in parallel with Swisstech since 2004

Who knocks PET bottles into shape

CorroPlastreg

ndash the ultimate steel forall-stainless mould sets

DEUTSCHE EDELSTAHLWERKE Obere Kaiserstr D-57078 Siegen Auestr 4 D-58452 Witten

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Industry News

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

Interactive Meusburger Catalogue Provides Free Standard Parts Calculation

Version 50 of the interactive CD catalogue issued by Meusburger the Austrian manufacturer of standard parts has many new features The catalogue software includes new products for mould making as well as the entire punching tool product range a recent addition to the Meusburger portfolio The company has prided itself on setting industry trends for digital catalogues and the advanced features in the latest CD version continue the customer-oriented tradition

The software is equipped with a mould assistant for injection moulding tools and a die-set assistant for punch-ing-tool construction Selecting various plates from a mod-ular system users can assemble mould tools and die sets with just a few clicks of the mouse The software then cal-culates all necessary accessories fully automatically and free of charge The CD catalogue includes 3D models of more than 46000 Meusburger products which are easily exported into all current CAD systems and as neutral data

By displaying individual prices for different customers the digital catalogue renders inquiries obsolete Also the integrated e-mail function makes ordering a faster and simpler process Useful search options and new group fil-ters (with pictures) help save time and effort in looking for products And finally an automatic update feature makes sure that users are working with the latest software and will not miss any newly introduced products

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo FIP Solution Plastique 2011Lyon Francewwwf-i-pcom

raquo Eberhard WerkzeugtechnologieNordheim Germanywwweberhardde

FIP 2011 Plastics Industry Exhibition Due in Lyon in May

Eberhard GmbH Enjoys a 28 Increase in Turnover in 2010

From May 24 to 27 the Rhocircne capital of Lyon will host FIP Solution Plastique 2011 the Plastics Industry Exhibition in France FIP is the only French trade show that brings all of the plastics industry players togeth-er in one place in this case the Lyon Eurexpo More than 500 exhibitors representing all aspects of the plas-tics industry will be on hand These include upstream suppliers of raw materials as well as producers or pro-viders of machines and equipment moulds and tools design services prototypes and models inspection technologies for quality control soft-ware and recycling technology Pro-cessors directly connected with final clients will be present in the area des-ignated FIPrsquoProjets

Because innovation is so important for companies wishing to stand out in

Gebruumlder Eberhard GmbH the par-ent company of the tool technology specialist Eberhard Werkzeugtech-nologie increased its turnover to just under euro90 million in 2010 a 28 rise Thus the company has managed to top the highest figure it had achieved before the period of economic crisis Meanwhile its staff increased by 10 last year to 440 employees

Eberhard GmbH manufactures stan-dard parts and accessories for tools in Nordheim and runs a specialized electrical retail outlet in Heilbronn as well as operating an additional tool technology production site in Thuringia and another electrical retail outlet in Saxony

Z 107101 Z 107105

The new universalneedle valvepermits the construction of compactmoulds and simplifies the integration of the needle valve systems in manyapplications

Unique flexibility in nozzle length and diameter

Can be used with all standard nozzles

Flexible valve pin strokeup to 7 mm

Available for 2 needle diameters (2 and 25 mm)

Flexible drive solutions Hydraulic internal or pneumatic external

No melt split in the diverting unit

Integration in stack and tandem moulds is possible

Minimum mounting space

HASCO Hasenclever GmbH+Co KGIm Wiesental 77 middot D-58513 LuumldenscheidTel +49 2351 957-0 middot Fax +49 2351 957-237E-mail infohascocom middot wwwhascocom

Together we shape your ideas

Improved colour change properties

the market FIP Solu-tion Plastique 2011 includes the Innova-tion Forum which offers a harmonized overview of recent industry develop-

ments Exhibitors in 15- to 20-minute speeches will unveil innovative solu-tions that resulted from advanced research and new technologies The trade fair also comprises a free con-ference programme and other edu-cational offerings to complement the Innovation Forum and FIPrsquoProjets

The 4th annual Caoutchouc Caucho Gomma international meeting of the rubber and polymer industries takes place at the same time as FIP Solution Plastique 2011 and also in the Lyon Eurexpo

The company benefited from the fact that it did not reduce its work-force in 2009 despite a significant decline in turnover In fact it made extensive investments and doubled the production area in Nordheim ldquoAfter all positive continuity is what sets down-to-earth family-owned companies apartrdquo says CEO Roland Eberhard Eberhard GmbH also expanded its vocational trainee pro-gramme and has signed contracts with a second generation of students at the Cooperative University

Industry News

16

Cover Story | Interview

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

A company with a strong pres-ence in Europe Meusburger

is a long-established specialist in the field of standard moulds In the past few years the Austrian enterprise has invested consider-able resources in expanding plant capacity in an effort to keep pace with its business growth Mean-while it introduced a completely new line of tool components to

enlarge an already bulging product catalogue

A strong position in the Euro-pean market is not alone enough for Meusburger Standard Moulds however The company founded a sales office in China in 2010 ETMM spoke with the companyrsquos managing director Guntram Meusburger son of the epony-mous founder about these and other aspects of Meusburgerrsquos present and future operations

ETMM Please give us a brief history of Meusburger GmbH How did the company start and how did it reach its present statureMeusburger ldquoConcentrating on our own strengthsrdquomdashthis slogan has been guiding Meusburger ever since 1964 The company started off as a one-man business and today employs 420 members of staff By continuously focusing on its own strengths clearly struc-tured processes the targeting of products to meet customer needs

and quality assurance Meusburg-er has become a European leader in the field of standard moulds which represents the companyrsquos main product line

Which industry sector is most impor-tant to your company and which sectors are you looking to develop furtherMeusburger stands for continu-ity and growthmdashand especially for high-quality products for the tool and mould making industry Last year we created space for some new things and we became very active in many other areas as well For example we prepared the introduction of a new field of businessmdashnamely punching tool

construction for which we have developed products We want to continue on this successful path in the coming year

We are particularly proud of our modular systemndashbased punch-ing-tool standard parts which are completely new However though these products are in fact new we have managed to adapt numerous well-known Meusburger advan-tages from our injection-mould-making range for use in construct-ing the punching tools

What recent or forthcoming new tech-nologies will bring your customers more value in the futureStress-relieved standard parts that is the obvious answer Playing a key role at the beginning of the process chain these components form a reliable foundation for high-quality moulds and tools The latest investment project of Meusburger has been additional furnaces with 120 tons of loading capacity per day With this invest-ment we increased the existing capacity by more than half

Stress-relieved standard parts in particular the parts for injec-tion moulds and punching dies offer many benefits to toolmak-ers We apply the stress-relieving

Concentrating on Strengths a Mould Industry Supplier GrowsMeusburger Standard Moulds has been successful for nearly half a century and its director suggests intends not to let up

ldquoMeusburger stands for continuity and growthmdashand especially for high-quality products for the tool and mould making industry We place great value on products that provide a clear added value for our customersrdquo

Managing Director Guntram Meusburger

wwwthebrightworldofmetalscom wwwgmtnde

One date ndash one place ndash four eventsMake the most of four high-calibre trade fairs ndash for foundry technology metallurgy thermo process technology and precision castings ndash in one place and with one entrance ticket

The industriesrsquo Number 1 worldwide multiple synergies connections and networks all in just one show visit Welcome to Duumlsseldorf

The Bright Worldof MetalsDuumlsseldorf Germany 28 June ndash 02 July 2011

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Interview

heat treatment to all grades of steel That is the best prerequisite for warp-free machining of parts

What do you consider to be Meusburgerrsquos most important product rangeManufacturing plates for injection moulding and punching tools clearly is our biggest strength in rela-tion to our competitors Meusburger uses the best raw materials and suppliers and we implement a programme of complete quality assurance through-out the production process

How important is research and development to Meus-burger Standard MouldsWe place great value on products that provide a clear added value for our customers Therefore we develop new products by working together with customers to fulfill not only their specific needs but also and especially the needs of the market generally

Is Meusburger GmbH active in AsiaIn 2010 we opened a new sales office in Wuxi China in Jiangsu Province The reason for that is that many of our customers have manufacturing operations in China and have expressed an inter-est in using standard products made by Meusburger there As a supplier of high-quality standard parts we naturally thought it was important for us to have an in-country sales office of our own

Incidentally from May 17 to May 20 this year Meusburger GmbH will be represented for the first time at the Chinaplas trade fair which is being held in the city of Guangzhou China We invite read-ers intending to visit that show to come see us at Stand D 41 in Hall 32

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

The investment of millions of euros in the Meusburger production facility in Wolfurt in recent years extended the companyrsquos capabilities For example new furnaces allow the standard parts manufacturer to produce stress-relieved components in greater volume

18

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Advanced series of customized hot runner systems a thoroughly innovative new solution

from DME has been designed to free mould makers from the limita-tions imposed by ldquohalf-

standardrdquo solutionsmdashthat is the use of standard

products to construct a special hot runner system

With the concept-products of the Advanced series the

moulder receives a fully cus-tomer-specific system tailored

to defined needs without any compromising that will perform

exactly as it should

This hot runner series was made possible by the development of sev-eral different nozzle tips with new openings These provide an opti-mal solution for every material and accommodate lateral-injection and multiple-gating requirements Within 24 hours of request DME will offer a quotation for a complex hot runner solution including a 3D drawing and a multiflow system if needed Deliv-ery of such a system can be expect-ed in 7 to 20 working days depend-ing on the complexity plus transport Expedited delivery also is available

raquo DME EuropeMechelen Belgiumwwwdmeeucom

Custom Hot Runners without Compromise Are Available via New System Solution

Rainer Knarr Vertriebs GmbH spe-cializes in the manufacture and sup-ply of standard and custom mould parts The company prides itself on including in its standards line mould accessories that other suppliers might offer only as specials

Beyond its extensive range of stan-dard components Rainer Knarr also provides custom mould components for tool and mould makers and injec-tion-moulders such as flat ejector pins with corner radius flat ejector pins with an extralong blade step-less sleeve ejectors pins that have a diamondlike-carbon (DLC) coating (photo) ejectors with an antitwist lock and many others All of these so-called standardized specials come in a wide range of stocked dimensions

The Rainer Knarr Group operates its own mould making division There-fore it well understands the needs and challenges of mould makers and

injection moulders The supplier sup-ports customers by offering a flexible ordering and deliv-ery servicemdashwith same-day shipping even for emergency orders received on Saturdaymdashan on-line shop and CAD data that is available for downloading

Always working on developing better solutions Rainer Knarr has recently launched several new product lines One is the huge XXL programme of flat ejector pins This line features pins in dimensions other than the well-known standard ones In addition it includes flat ejec-tors with corner radii and a DLC coat-ing flat ejectors with a long sheet and high-speed flat ejectors

Another line con-sists of patented hardened or nitrid-ed stepless ejector sleeves designed to facilitate reduction of the guide length

Also new from Rainer Knarr is a range of waved deflection baffles made of plastic which help ensure efficient balanced

mould cooling And the last highlight-ed recent introduction from the com-pany is a series of ejectors for outline pins that are made of hot-working steel hardened to 53 HRc for opti-mum machinability

Service-Oriented Supplier Provides Standard Mould Parts and Standardized Specials

raquo Rainer Knarr Vertriebs GmbHHelmbrechts Germanywwwrainer-knarrde

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

I remember when most tool and mould makers would

not have been very likely to use digital media But those days have gone

Over the past decade we have seen a lot of changes in digitally delivered content and also in the way mould makers interface with the World Wide Web Irsquom not

talking about transferring design data or other soft-ware artifacts over the Internet or communicating via e-mail I mean that they use the Internet to find the information they need to stay up-to-date remain competitive and make money

ldquoKnowledge is powerrdquo as the saying goes and between print and digital media a wealth of knowl-edge is available today We are watching the commu-nications revolution as it happens and we at ETMM are excited about all the new opportunities we have for delivering necessary information Here in Europe print media is still dominant in information delivery However as digital technology comes to play a more and more important role the communication pro-cess grows ever more efficient

There are several ways for tool and mould mak-ers to use digital media They can visit suppliersrsquo websites of course Then there are Google Ping and Wikipedia for gathering general information For more-specific information about the tool and mould making industry the choices are fewer but the ETMM family of digital products gives our read-ers an on-line platform they can count on This plat-form consists of the website (wwwetmm-onlinecom) a weekly e-newsletter and a monthly buyerrsquos guide update with a product newsletter

If you have not yet visited our website or signed up to get the weekly newsletter or monthly buyerrsquos guide update please go to wwwetmm-onlinecom to see for yourself what is available on-line

Digital Media and Mould Making CUTTING TOOL COMPANY

JAPANrsquoS NOCUTTING TOOL COMPANYUUTT IINGG TOOOOLL CCOOMMPPAANNYY

Mitsubishi House Galena CloseTamworth Staffs B77 4AS Tel + 44 (0) 1827 312312E-Mail salesmitsubishicarbidecoukwwwmitsubishicarbidecom

ANTI VIBRATIONEND MILLS

New generation for higher feed rates and greater depths of cutIMPACT MIRACLE coating for the ultimate in hard material millingVibration control geometry for a stable smooth cutting actionAvailable in a wide range of geometries and sizes Oslash2 - Oslash20mm

VF SERIES

Douglas SellersMANAGING DIRECTOREDITOR-IN-CHIEF

Editorrsquos Message

4

Table of Contents

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Interview 16Concentrating on Strengths a Mould Industry Supplier Grows

Product Focus 18Recently introduced products from suppliers of tool and mould components and hot runner technology

Quick Sourcing Grid Tool amp Mould Components 22A handy table of companies supplying components to the tool and mould making industry cross-indexed by more than 40 categories

Quick Sourcing Grid Hot Runner Systems and Components 26A handy table of companies supplying hot runner technology to the tool and mould making industry

COVER STORY

Editorrsquos Message 3As digital communication tools such as those ETMM offers appear and develop tool and mould makers stand to benefit

Industry News 7Corporate professional and educational events that define the direction of the industry

Technology28Hydrogen-Free DLC Coatings Make Tools Hard and Smooth

Technology30New Geometries Make Revised Drilling System More Efficient

Cover photo provided byMeusburger Georg GmbH amp Co KGKesselstraszlige 426960 Wolfurt AustriaTel +43 5574 67060Fax +43 5574 670611wwwmeusburgercom

Case Study 32PPS Software Ups Production Transparency for Mould Maker

Case Study 34Using a Powerful Yet Sensitive Tryout Press to Finish the Job

Case Study 36Forging Company Makes Dies from Tough Hard Tool Steel

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Tuumlrk+Hillinger GmbH78532 Tuttlingen Germany

Tel +49 74 61 70 140 Fax +49 74 61 70 1410

infotuerk-hillingerde

wwwtuerk-hillingerde

since 1963

we are your best choice forheating elements

wide product range

large repertory of stock types

customer-specific executions

modern rational manufacturing methods

over 30000 heating elements daily

certified according to DIN ISO 90012000

high life span

500 qualified employees

over 240 patent applications

made in Germany

June 2011The focus of the Cover Story in the next issue of ETMM is Machining Equipment This section will include an overview article short Product Focus articles and a Quick Sourcing Grid of equipment suppliers serving the tool and mould making industry

The June issue also offers bull A Special Report focusing on mould making in Russia and a

EuroMold perspective on the RosMould exhibitionbull A Technology section focus on cutting tools and machining

accessories for tool and mould makersbull The Summer 2011 issue of EDM Europe

NEXT ISSUE

Volume XIII | Issue 4 | May 2011

Case Study 38Compact 3D Printer Expands Development Firmrsquos Horizons

Products amp Services 40Recently introduced equipment and services from all over

ISTMA 49Directory of ISTMA Europe Member Associations

Company Index 50A listing of the industry suppliers who supported this issue with articles and advertisements

TRU

MPF

GRO

UP

Table of Contents

VOLUME XIII NUMBER 4 MAY 2011

EUROPEAN TOOL amp MOULD MAKINGPublished by SellersMedia

P U B L I S H E R E D I T O R - I N - C H I E F

Douglas Sellersdsellerssellersmediacom

SELLERSMEDIAOtto-von-Guericke-Ring 3A 65205 Wiesbaden Germany

Tel +49 6122 95590 bull Fax +49 6122 51090infoetmm-onlinecomwwwetmm-onlinecom

P R O D U C T I O N C I R C U L AT I O N amp I N F O R M AT I O N S E R V I C E S

Briggette Jayabjayasellersmediacom

Melanie Rosselmrosselsellersmediacom

G R A P H I C D E S I G N E R S

Jason Sellersjsellerssellersmediacom

Law Wai Manlwmsellersmediacom

I N F O R M AT I O N T E C H N O L O G Y S P E C I A L I S T

Markus Muumlllermmuellersellersmediacom

S A L E S M A N A G E R

Britta Sollowaybsollowaysellersmediacom

A D V E R T I S I N G S A L E S F R A N C E

Evelyne Gisselbrecht33 Rue du Puy-de-Docircme 63370 Lempdes France

Tel +33 473 619557 bull Fax +33 473 619661egisselbrechtsellersmediacom

R E P R E S E N TAT I V E A G E N T F O R TA I WA N C H I N A amp H O N G KO N G

Robert Yu Worldwide Services Co Ltd11F-B No 540 Wen Hsin Road Section 1 Taichung 408 Taiwan

Tel +886 4 23251784 bull Fax +886 4 23252967saleswwstaiwancom

N O R T H A M E R I C A N O F F I C E30765 Pacific Coast Highway PMB 351

Malibu CA 90265-3643 USATel +1 805 744-7924 bull Fax +1 310 507-2032

usofficetool-moldmakingcom

B U S I N E S S M A N A G E R

MiSook Musselmanmmusselmantool-moldmakingcom

EDITORIAL CONTRIBUTIONS Productservice information bulletins and press releases should be submitted in English and should be accompanied by a colour photograph or transparency The publishers assume no responsibility for return of artwork photographs or manuscripts NOTICE Every precaution is taken to ensure accuracy of contents however the publishers cannot accept responsibility for the correctness of the information supplied or advertised or for any opinion expressed herein

SUBSCRIPTIONS European Tool amp Mould Making is published 10 times per year

Annual subscription in Europe euro 7900 incl VAT (1 year) euro 15000 incl VAT (2 years)Readers outside Europe euro 9900 incl VAT (1 year) euro 18500 incl VAT (2 years)

Single copies euro 1100 incl VAT

Subscription inquiries back issues address changes send your request to European Tool amp Mould Makingby e-mail to etmmtool-moldmakingcom or by fax to +49 6122 51090

Circulation Audit Member of the Informationsgemeinschaft zur Feststellung der Verbreitung von Werbetraumlgern eV (IVW) Berlin

Printed at Koumlssinger AG wwwkoessingerde

Copyright copy 2011 ACCESS COMMUNICATIONS INC ALL RIGHTS RESERVED

OfficialMedia Partner of

ISTMA Europe

7

Industry News

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

More visitors an even more interna-tional character and the best pos-sible accompanying programme of events elucidating current industry trends are the objectives of the orga-nizer and sponsors of AMB 2012 the International Exhibition for Metal-working Messe Stuttgart along with the Precision Tools Association of the VDMA (German Engineering Federa-tion) the VDMA Software Association and the VDW (German Machine Tool Buildersrsquo Association) want the show

handling apparatus Nearly a quar-ter of the exhibiting companies last year came from a record 80 coun-tries outside Germany and the pro-portion of foreign visitors increased between 2008 and 2010 from 7 to 11 Messe Stuttgart is focusing on increasing the eventrsquos international-ization further in 2012

Organizer of AMB 2012 Building on Success

raquo AMB 2012Stuttgart Germanywwwmesse-stuttgartde

which takes place September 18ndash22 in Stuttgart to surpass the signal suc-cess of the 2010 edition which fully satisfied the more than 1300 exhibi-tors and 86000 visitors

Fully booked halls are expected again in 2012 with the exhibition occupying an area of 105000 m2 Exhibitors will be displaying main-ly milling machines lathes cutting tools chucking tools CADCAMCAE and other software grinding machines and workpiece- and tool-

RosMould 2011 Comes to Moscow in June

RosMould 2011 the special-ized international exhibition for moulds die moulds and stamps taking place June 15ndash17 at the Crocus Expo in Moscow is as the organizer Expo-M-Group Ltd says the only such trade fair offered within the post-Soviet Russian ter-ritory The show has relevance for all manufacturing sectors

Also notes Expo-M-Group the global economic crisis is becom-ing less of a factor in the field of moulds dies and stamps as pro-duction picks up in Russia and elsewhere Investors in produc-tion equipment are ready again to spend on the sort of technological advances in design and engineer-ing simulation and prototyping production software tooling die moulds and stamps materials metalworking and forming equip-ment automation and QC sys-tems and standard components RosMould exhibitors present

RosMould 2011 is co-located with RosPlast the specialized exhibition for plastics technology and products

raquo RosMould 2011Moscow Russiawwwrosmouldcom

Watch Mastercam circle the globe at wwwtinyurlcommcglobe

8

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

With more than 15000 installed seats of its CAM software world-wide and a global network of more than 120 resellers in 50 countries SolidCAM GmbH has enjoyed great success The companyrsquos biggest mar-ket is Germany where some 2000 users are working

The CAM Competence Centre of

Husky Injection Molding Systems is expected to complete its acquisition of KTW a global manufacturer of clo-sure moulds that is headquartered in Waidhofen Austria in May 2011 The purchase represents a logical next step in a 14-year relationship between the companies

Husky and KTW have worked together to develop closure manu-facturing systems that enhance cus-tomersrsquo productivity while eliminat-ing waste and improving part quality explains John Galt Husky president and CEO But even closer collaboration was seen to be necessary for meeting

DPS Software GmbH has contributed nicely to this success in Germany as was acknowledged during a recent ceremony at SolidCAM headquarters in Schramberg There Stephan Ter-horst the software developerrsquos Ger-man marketing director presented the award for most successful world-wide SolidCAM reseller in 2010 to Joumlrg

Rudig (at right in photo) the manager of the DPS CAM Competence Centre and his staff of 13

DPS Software has 13 subsidiaries and 145 employees making it one of the biggest product lifecycle manage-ment project partners in Germany Austria and Switzerland An important growth engine for the companyrsquos prow-ess in integrated CAD CAE CAM PDM and ERP software solutions and related services is its CAM Compe-tence Centre Since the time the cen-tre was founded in 2000 the com-petence centre team has provided an integrated SolidWorksSolidCAM CADCAM solution for more than 1500 CNC machines As Joumlrg Rudig points out a key part of DPSrsquos service offering is the provision of customer-oriented training programmes to sup-port its CADCAM products

increasingly high expectations partic-ularly in developing the core elements of closure systems

Husky will offer KTW-branded clo-sure moulds as part of its line of fully integrated turnkey systems when the deal is concluded making it the clo-sure industryrsquos only provider of com-plete injection moulding systems including the mould machine hot runner and temperature controller as well as consulting and after-sales ser-vices KTW managing directors Anja and Claus Ziegler will continue to be involved at the top management level

KTW operations in Austria the Czech Republic and Germany are to become Huskyrsquos closure mould devel-opment and manufacturing cen-tres of excellence In addition Husky plans to initiate a strategic review of KTWrsquos custom injection mould-ing division Injectoplast in order to ensure the divisionrsquos future success and avoid potential conflicts of inter-est with its own customers

SolidCAM Presents DPS Software with Global Best Reseller Award for 2010

raquo SolidCAM GmbHSchramberg Germanywwwsolidcamde

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Husky Solidifies Its Position in Closure-Mould Market through Acquisition of KTW

Molded to your needs

www3dscommoldandtooling

Mold amp ToolingBoost your efficiency and save time with a robust and innovative approach

CATIA Mold amp Tooling brings the extra added value of an integrated end-to-end solution From design and engineering to simulation and manufacturing take advantage of proven

optimized processes to satisfy the increasing expectations of your customers

ww

w3

dsc

om

copy

Das

saul

t Sy

stegravem

es 2

011

ndash A

ll ri

ghts

rese

rved

ndash C

ATI

A is

a re

gist

ered

tra

dem

ark

of D

assa

ult

Syst

egravemes

or

its

subs

idia

ries

in t

he U

S an

d

or o

ther

cou

ntri

es

10

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Industry News

New President for Sandvik Materials Technology

Mastercam for SolidWorks Wins Gold Partner Status

Peter Gossas president of Sandvik Materials Tech-nology for nine years will retire and leave the Sand-vik Group on May 31 2011 Jonas Gustavsson (pictured) currently president of the Wire and Heating Technol-ogy product area within Sandvik Materials Technol-ogy has been appointed as the business divisionrsquos new president He also becomes

a member of Sandvikrsquos group executive managementSandvik Materials Technology is the Sandvik business

area that supplies metalworking materials It occupies a position within the group equivalent to that of Sandvik Coromant the cutting-tools division

Gustavsson who earned a degree in mechanical engi-neering from Lulearing Technical University has acquired solid industry experience by holding senior positions within and outside Sandvik Says Olof Faxander president and CEO of Sandvik AB ldquoWith his broad background and proven ability

The Mastercam for SolidWorksreg software package developed by CNC Software Inc to support Solid-Worksreg 3D CAD software has been awarded Certified Gold Partner status by Dassault Systegravemes SolidWorks Corp Designers engineers and machinists use Mas-tercam for SolidWorks software to programme tool paths after designs have been finished in SolidWorks The tool paths are applied directly to the SolidWorks model in their native environment Thus users of Mastercam for SolidWorks and SolidWorks 2011 in combination can employ Mastercamreg CAM technolo-gy to create a machining programme without leaving the SolidWorks interface

ldquoWith our tool paths running directly in the Solid-Works environment our users will feel comfortable programming their parts just as if they were in stan-dard Mastercamrdquo explains CNC Software marketing manager Ben Mund ldquoThe beauty is that now they can run those tool paths inside of SolidWorks with-out the hassle of exporting files and handling the translationrdquo

The point of the cooperation as Nick Iwaskow SolidWorksrsquo manager of alliances points out is that ldquointegration between key product design applica-tions can shave precious time off of the develop-ment process and increase productivityrdquo Ultimately designers and engineers can improve their designs

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

raquo CNC Software IncTolland CT USAwwwmastercamcom

STRACK NORMAGmbH amp Co KGKoumlnigsberger Str 11D-58511 Luumldenscheid

Tailor - MadeSolutions

NEW

CENTRING ELEMENTSfree of play bull wear-free bull with needle rollers

Tel +49 (0) 2351 8701-0Fax +49 (0) 2351 8701-100wwwstrackdeinfostrackde

to successfully drive change Jonas Gustavsson has the right profile to lead Sandvik Materials Technologyrdquo

Faxander also acknowledges the achievements of Gos-sas noting that the outgoing president could take credit for moving the product programme increasingly toward high-value-added products improving manufacturing pro-cesses and stepping up product development

11

Industry News

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

phone +49 (0) 92529993-0

fax +49 (0) 92529993-33

vertriebrainer-knarrde

wwwrainer-knarrde

Visit us

hall 4 booth D62

- shaft without bulge

- head underneath and

head diameter ground

- height of head 0-003

- suitable as contour pin

- high temperature resistance

- ability for coating and nitration

- wide range of dimensions

Contact UK and Ireland

Gunther UK Limited

phone 01474879774

infogunthercouk

Contact Czech Republic

wwwrsmplastcz

ISO 90012008

certified

Innovative waved

baffle profile

- shorter cycle times

- improved cooling-effect

- swirl of the medium

- prolongable up to 625mm

- temperature resistant 200degC max

Protected

system

Reduce cycle times with the new generation of

cooling deflection baffles

Ejectors - outline pins

hardened approx 53 HRC

With 78 manufacturers suppliers and service providers from the addi-tive technologies sector having con-firmed their participation as exhibi-tors at EuroMold 2011 the trade fair for mould making and tooling design and application development is extending its claim to be the most important European marketplace for this growing industrial field also known as e-production Numerous market-leading innovators specializ-ing in additive manufacturing will be presenting themselves at the Frank-furt Exhibition Centre November 29 through December 2 particularly in Hall 11

The EuroMold organizer DEMAT GmbH has provided additional show-cases for the additive technologies sector through its offer of the uni-

versity researchndashbased special-focus show within a show ldquoe-Production for Everyonerdquo this year in its third edi-tion and the globally renowned Inter-national Wohlers Conference In 2011 the 13th Wohlers Conference will feature an emphasis on design in the production of additives

E-production experts think 2011 will be a year of strong growth driven by the release of pent-up demand for new product development technol-

ogies and services ldquoAs companies investigate additive manufacturing for the production of end-use prod-ucts a new level of technology adop-tion will unfoldrdquo says Terry Wohlers CEO of Wohlers Associates Inc

EuroMold 2011 presents the entire spectrum of additive technologies and their uses including 3D-printed products for industrial applications Among the top global companies dis-playing their latest materials tech-nologies and applications will be 3D Systems Alphacam Concept Laser EOS FIT Huntsman Materialise MTT Objet Realizer SLM Solutions Strata-sys and Z Corp

EuroMold 2011 Is Planned to Solidify Position As Premiere Additive Technologies Marketplace

raquo EuroMold 2011FrankfurtMain Germanywwweuromoldcom

EURO

MO

LD

12

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

In Sosnowiec Poland prepara-tions are in full swing for Toolex 2011 the International Machine Tools Tools and Processing Tech-nology Fair which is scheduled to take place October 5ndash7 at the Expo Silesia Exhibition Cen-tre This prestigious event for the metal-processing industry attracts more and more indus-try experts every year In 2010 more than 6000 professional and expert show visitors were very satisfied by what they found at the 167 exhibition stands showcasing over 350 companies from more than two dozen coun-tries around the world

Toolex always offers a compre-hensive presentation of machine tools specialized tools tech-nological equipment software and measuring and control instruments including world premieres of many machines and tools Last year in an exhibition area extending over more than 4000 m2 181 metal-processing machine tools on display were in full operation The venue is equipped to allow exhibitors to display large and

complex operating machines includ-ing entire assembly lines

The exhibition facility in Sosno wiec is situated in the heart of Polandrsquos most industrial region which is also an important scientific centre The area of Silesia and Zaglebie is home to a range of fast-growing industri-al sectors such as the automotive

aviation and mechanical engineer-ing industries among others Also the Czech Republic and Slovakia are nearby Transportation access to the venue is well developed

Expo Silesia Expects Toolex 2011 to Be Another Successful Metal-Processing Fair

raquo Toolex 2011Sosnowiec Polandwwwtoolexpl

MCH Swiss Exhibition (Basel) Ltd has handed over the organization and operation of Swisstech Europersquos Central Fair for the Subcontracting Industries to its wholly owned sub-sidiary Exhibit amp More AG The latter company now is in charge of Swiss-tech 2012 scheduled for November 20ndash23 2012 in Basel Exhibit amp More headquartered near Zuumlrich has been organizing specialist industrial fairs for more than 30 years

Swisstech is a key meeting point

The MCH Group assumed full con-trol of Exhibit amp More at the beginning of 2010 The managers of both trade fair organizing entities are convinced that the merger of their forces will make it possible to position Swisstech and Prodex in the market more effi-ciently and to steer a course toward a successful future

Swisstech Fair Henceforward in Hands of MCH Messe Basel Subsidiary Exhibit amp More

raquo Exhibit amp More AGFaumlllanden-Zuumlrich Switzerlandwwwexhibitandmorech

every two years for the subcontract-ing industry companies operating in the fields of procurement manu-facturing and production technolo-gy MCHmdashalso known as MCH Messe Baselmdashhas used Swisstech to high-light the synergies that exist between the mechanical engineering industry and the world of specialist suppliers It has also organized Prodex the spe-cialist exhibition for machine tools tools and production measurement in parallel with Swisstech since 2004

Who knocks PET bottles into shape

CorroPlastreg

ndash the ultimate steel forall-stainless mould sets

DEUTSCHE EDELSTAHLWERKE Obere Kaiserstr D-57078 Siegen Auestr 4 D-58452 Witten

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Industry News

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

Interactive Meusburger Catalogue Provides Free Standard Parts Calculation

Version 50 of the interactive CD catalogue issued by Meusburger the Austrian manufacturer of standard parts has many new features The catalogue software includes new products for mould making as well as the entire punching tool product range a recent addition to the Meusburger portfolio The company has prided itself on setting industry trends for digital catalogues and the advanced features in the latest CD version continue the customer-oriented tradition

The software is equipped with a mould assistant for injection moulding tools and a die-set assistant for punch-ing-tool construction Selecting various plates from a mod-ular system users can assemble mould tools and die sets with just a few clicks of the mouse The software then cal-culates all necessary accessories fully automatically and free of charge The CD catalogue includes 3D models of more than 46000 Meusburger products which are easily exported into all current CAD systems and as neutral data

By displaying individual prices for different customers the digital catalogue renders inquiries obsolete Also the integrated e-mail function makes ordering a faster and simpler process Useful search options and new group fil-ters (with pictures) help save time and effort in looking for products And finally an automatic update feature makes sure that users are working with the latest software and will not miss any newly introduced products

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo FIP Solution Plastique 2011Lyon Francewwwf-i-pcom

raquo Eberhard WerkzeugtechnologieNordheim Germanywwweberhardde

FIP 2011 Plastics Industry Exhibition Due in Lyon in May

Eberhard GmbH Enjoys a 28 Increase in Turnover in 2010

From May 24 to 27 the Rhocircne capital of Lyon will host FIP Solution Plastique 2011 the Plastics Industry Exhibition in France FIP is the only French trade show that brings all of the plastics industry players togeth-er in one place in this case the Lyon Eurexpo More than 500 exhibitors representing all aspects of the plas-tics industry will be on hand These include upstream suppliers of raw materials as well as producers or pro-viders of machines and equipment moulds and tools design services prototypes and models inspection technologies for quality control soft-ware and recycling technology Pro-cessors directly connected with final clients will be present in the area des-ignated FIPrsquoProjets

Because innovation is so important for companies wishing to stand out in

Gebruumlder Eberhard GmbH the par-ent company of the tool technology specialist Eberhard Werkzeugtech-nologie increased its turnover to just under euro90 million in 2010 a 28 rise Thus the company has managed to top the highest figure it had achieved before the period of economic crisis Meanwhile its staff increased by 10 last year to 440 employees

Eberhard GmbH manufactures stan-dard parts and accessories for tools in Nordheim and runs a specialized electrical retail outlet in Heilbronn as well as operating an additional tool technology production site in Thuringia and another electrical retail outlet in Saxony

Z 107101 Z 107105

The new universalneedle valvepermits the construction of compactmoulds and simplifies the integration of the needle valve systems in manyapplications

Unique flexibility in nozzle length and diameter

Can be used with all standard nozzles

Flexible valve pin strokeup to 7 mm

Available for 2 needle diameters (2 and 25 mm)

Flexible drive solutions Hydraulic internal or pneumatic external

No melt split in the diverting unit

Integration in stack and tandem moulds is possible

Minimum mounting space

HASCO Hasenclever GmbH+Co KGIm Wiesental 77 middot D-58513 LuumldenscheidTel +49 2351 957-0 middot Fax +49 2351 957-237E-mail infohascocom middot wwwhascocom

Together we shape your ideas

Improved colour change properties

the market FIP Solu-tion Plastique 2011 includes the Innova-tion Forum which offers a harmonized overview of recent industry develop-

ments Exhibitors in 15- to 20-minute speeches will unveil innovative solu-tions that resulted from advanced research and new technologies The trade fair also comprises a free con-ference programme and other edu-cational offerings to complement the Innovation Forum and FIPrsquoProjets

The 4th annual Caoutchouc Caucho Gomma international meeting of the rubber and polymer industries takes place at the same time as FIP Solution Plastique 2011 and also in the Lyon Eurexpo

The company benefited from the fact that it did not reduce its work-force in 2009 despite a significant decline in turnover In fact it made extensive investments and doubled the production area in Nordheim ldquoAfter all positive continuity is what sets down-to-earth family-owned companies apartrdquo says CEO Roland Eberhard Eberhard GmbH also expanded its vocational trainee pro-gramme and has signed contracts with a second generation of students at the Cooperative University

Industry News

16

Cover Story | Interview

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

A company with a strong pres-ence in Europe Meusburger

is a long-established specialist in the field of standard moulds In the past few years the Austrian enterprise has invested consider-able resources in expanding plant capacity in an effort to keep pace with its business growth Mean-while it introduced a completely new line of tool components to

enlarge an already bulging product catalogue

A strong position in the Euro-pean market is not alone enough for Meusburger Standard Moulds however The company founded a sales office in China in 2010 ETMM spoke with the companyrsquos managing director Guntram Meusburger son of the epony-mous founder about these and other aspects of Meusburgerrsquos present and future operations

ETMM Please give us a brief history of Meusburger GmbH How did the company start and how did it reach its present statureMeusburger ldquoConcentrating on our own strengthsrdquomdashthis slogan has been guiding Meusburger ever since 1964 The company started off as a one-man business and today employs 420 members of staff By continuously focusing on its own strengths clearly struc-tured processes the targeting of products to meet customer needs

and quality assurance Meusburg-er has become a European leader in the field of standard moulds which represents the companyrsquos main product line

Which industry sector is most impor-tant to your company and which sectors are you looking to develop furtherMeusburger stands for continu-ity and growthmdashand especially for high-quality products for the tool and mould making industry Last year we created space for some new things and we became very active in many other areas as well For example we prepared the introduction of a new field of businessmdashnamely punching tool

construction for which we have developed products We want to continue on this successful path in the coming year

We are particularly proud of our modular systemndashbased punch-ing-tool standard parts which are completely new However though these products are in fact new we have managed to adapt numerous well-known Meusburger advan-tages from our injection-mould-making range for use in construct-ing the punching tools

What recent or forthcoming new tech-nologies will bring your customers more value in the futureStress-relieved standard parts that is the obvious answer Playing a key role at the beginning of the process chain these components form a reliable foundation for high-quality moulds and tools The latest investment project of Meusburger has been additional furnaces with 120 tons of loading capacity per day With this invest-ment we increased the existing capacity by more than half

Stress-relieved standard parts in particular the parts for injec-tion moulds and punching dies offer many benefits to toolmak-ers We apply the stress-relieving

Concentrating on Strengths a Mould Industry Supplier GrowsMeusburger Standard Moulds has been successful for nearly half a century and its director suggests intends not to let up

ldquoMeusburger stands for continuity and growthmdashand especially for high-quality products for the tool and mould making industry We place great value on products that provide a clear added value for our customersrdquo

Managing Director Guntram Meusburger

wwwthebrightworldofmetalscom wwwgmtnde

One date ndash one place ndash four eventsMake the most of four high-calibre trade fairs ndash for foundry technology metallurgy thermo process technology and precision castings ndash in one place and with one entrance ticket

The industriesrsquo Number 1 worldwide multiple synergies connections and networks all in just one show visit Welcome to Duumlsseldorf

The Bright Worldof MetalsDuumlsseldorf Germany 28 June ndash 02 July 2011

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Interview

heat treatment to all grades of steel That is the best prerequisite for warp-free machining of parts

What do you consider to be Meusburgerrsquos most important product rangeManufacturing plates for injection moulding and punching tools clearly is our biggest strength in rela-tion to our competitors Meusburger uses the best raw materials and suppliers and we implement a programme of complete quality assurance through-out the production process

How important is research and development to Meus-burger Standard MouldsWe place great value on products that provide a clear added value for our customers Therefore we develop new products by working together with customers to fulfill not only their specific needs but also and especially the needs of the market generally

Is Meusburger GmbH active in AsiaIn 2010 we opened a new sales office in Wuxi China in Jiangsu Province The reason for that is that many of our customers have manufacturing operations in China and have expressed an inter-est in using standard products made by Meusburger there As a supplier of high-quality standard parts we naturally thought it was important for us to have an in-country sales office of our own

Incidentally from May 17 to May 20 this year Meusburger GmbH will be represented for the first time at the Chinaplas trade fair which is being held in the city of Guangzhou China We invite read-ers intending to visit that show to come see us at Stand D 41 in Hall 32

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

The investment of millions of euros in the Meusburger production facility in Wolfurt in recent years extended the companyrsquos capabilities For example new furnaces allow the standard parts manufacturer to produce stress-relieved components in greater volume

18

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Advanced series of customized hot runner systems a thoroughly innovative new solution

from DME has been designed to free mould makers from the limita-tions imposed by ldquohalf-

standardrdquo solutionsmdashthat is the use of standard

products to construct a special hot runner system

With the concept-products of the Advanced series the

moulder receives a fully cus-tomer-specific system tailored

to defined needs without any compromising that will perform

exactly as it should

This hot runner series was made possible by the development of sev-eral different nozzle tips with new openings These provide an opti-mal solution for every material and accommodate lateral-injection and multiple-gating requirements Within 24 hours of request DME will offer a quotation for a complex hot runner solution including a 3D drawing and a multiflow system if needed Deliv-ery of such a system can be expect-ed in 7 to 20 working days depend-ing on the complexity plus transport Expedited delivery also is available

raquo DME EuropeMechelen Belgiumwwwdmeeucom

Custom Hot Runners without Compromise Are Available via New System Solution

Rainer Knarr Vertriebs GmbH spe-cializes in the manufacture and sup-ply of standard and custom mould parts The company prides itself on including in its standards line mould accessories that other suppliers might offer only as specials

Beyond its extensive range of stan-dard components Rainer Knarr also provides custom mould components for tool and mould makers and injec-tion-moulders such as flat ejector pins with corner radius flat ejector pins with an extralong blade step-less sleeve ejectors pins that have a diamondlike-carbon (DLC) coating (photo) ejectors with an antitwist lock and many others All of these so-called standardized specials come in a wide range of stocked dimensions

The Rainer Knarr Group operates its own mould making division There-fore it well understands the needs and challenges of mould makers and

injection moulders The supplier sup-ports customers by offering a flexible ordering and deliv-ery servicemdashwith same-day shipping even for emergency orders received on Saturdaymdashan on-line shop and CAD data that is available for downloading

Always working on developing better solutions Rainer Knarr has recently launched several new product lines One is the huge XXL programme of flat ejector pins This line features pins in dimensions other than the well-known standard ones In addition it includes flat ejec-tors with corner radii and a DLC coat-ing flat ejectors with a long sheet and high-speed flat ejectors

Another line con-sists of patented hardened or nitrid-ed stepless ejector sleeves designed to facilitate reduction of the guide length

Also new from Rainer Knarr is a range of waved deflection baffles made of plastic which help ensure efficient balanced

mould cooling And the last highlight-ed recent introduction from the com-pany is a series of ejectors for outline pins that are made of hot-working steel hardened to 53 HRc for opti-mum machinability

Service-Oriented Supplier Provides Standard Mould Parts and Standardized Specials

raquo Rainer Knarr Vertriebs GmbHHelmbrechts Germanywwwrainer-knarrde

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

4

Table of Contents

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Interview 16Concentrating on Strengths a Mould Industry Supplier Grows

Product Focus 18Recently introduced products from suppliers of tool and mould components and hot runner technology

Quick Sourcing Grid Tool amp Mould Components 22A handy table of companies supplying components to the tool and mould making industry cross-indexed by more than 40 categories

Quick Sourcing Grid Hot Runner Systems and Components 26A handy table of companies supplying hot runner technology to the tool and mould making industry

COVER STORY

Editorrsquos Message 3As digital communication tools such as those ETMM offers appear and develop tool and mould makers stand to benefit

Industry News 7Corporate professional and educational events that define the direction of the industry

Technology28Hydrogen-Free DLC Coatings Make Tools Hard and Smooth

Technology30New Geometries Make Revised Drilling System More Efficient

Cover photo provided byMeusburger Georg GmbH amp Co KGKesselstraszlige 426960 Wolfurt AustriaTel +43 5574 67060Fax +43 5574 670611wwwmeusburgercom

Case Study 32PPS Software Ups Production Transparency for Mould Maker

Case Study 34Using a Powerful Yet Sensitive Tryout Press to Finish the Job

Case Study 36Forging Company Makes Dies from Tough Hard Tool Steel

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Tuumlrk+Hillinger GmbH78532 Tuttlingen Germany

Tel +49 74 61 70 140 Fax +49 74 61 70 1410

infotuerk-hillingerde

wwwtuerk-hillingerde

since 1963

we are your best choice forheating elements

wide product range

large repertory of stock types

customer-specific executions

modern rational manufacturing methods

over 30000 heating elements daily

certified according to DIN ISO 90012000

high life span

500 qualified employees

over 240 patent applications

made in Germany

June 2011The focus of the Cover Story in the next issue of ETMM is Machining Equipment This section will include an overview article short Product Focus articles and a Quick Sourcing Grid of equipment suppliers serving the tool and mould making industry

The June issue also offers bull A Special Report focusing on mould making in Russia and a

EuroMold perspective on the RosMould exhibitionbull A Technology section focus on cutting tools and machining

accessories for tool and mould makersbull The Summer 2011 issue of EDM Europe

NEXT ISSUE

Volume XIII | Issue 4 | May 2011

Case Study 38Compact 3D Printer Expands Development Firmrsquos Horizons

Products amp Services 40Recently introduced equipment and services from all over

ISTMA 49Directory of ISTMA Europe Member Associations

Company Index 50A listing of the industry suppliers who supported this issue with articles and advertisements

TRU

MPF

GRO

UP

Table of Contents

VOLUME XIII NUMBER 4 MAY 2011

EUROPEAN TOOL amp MOULD MAKINGPublished by SellersMedia

P U B L I S H E R E D I T O R - I N - C H I E F

Douglas Sellersdsellerssellersmediacom

SELLERSMEDIAOtto-von-Guericke-Ring 3A 65205 Wiesbaden Germany

Tel +49 6122 95590 bull Fax +49 6122 51090infoetmm-onlinecomwwwetmm-onlinecom

P R O D U C T I O N C I R C U L AT I O N amp I N F O R M AT I O N S E R V I C E S

Briggette Jayabjayasellersmediacom

Melanie Rosselmrosselsellersmediacom

G R A P H I C D E S I G N E R S

Jason Sellersjsellerssellersmediacom

Law Wai Manlwmsellersmediacom

I N F O R M AT I O N T E C H N O L O G Y S P E C I A L I S T

Markus Muumlllermmuellersellersmediacom

S A L E S M A N A G E R

Britta Sollowaybsollowaysellersmediacom

A D V E R T I S I N G S A L E S F R A N C E

Evelyne Gisselbrecht33 Rue du Puy-de-Docircme 63370 Lempdes France

Tel +33 473 619557 bull Fax +33 473 619661egisselbrechtsellersmediacom

R E P R E S E N TAT I V E A G E N T F O R TA I WA N C H I N A amp H O N G KO N G

Robert Yu Worldwide Services Co Ltd11F-B No 540 Wen Hsin Road Section 1 Taichung 408 Taiwan

Tel +886 4 23251784 bull Fax +886 4 23252967saleswwstaiwancom

N O R T H A M E R I C A N O F F I C E30765 Pacific Coast Highway PMB 351

Malibu CA 90265-3643 USATel +1 805 744-7924 bull Fax +1 310 507-2032

usofficetool-moldmakingcom

B U S I N E S S M A N A G E R

MiSook Musselmanmmusselmantool-moldmakingcom

EDITORIAL CONTRIBUTIONS Productservice information bulletins and press releases should be submitted in English and should be accompanied by a colour photograph or transparency The publishers assume no responsibility for return of artwork photographs or manuscripts NOTICE Every precaution is taken to ensure accuracy of contents however the publishers cannot accept responsibility for the correctness of the information supplied or advertised or for any opinion expressed herein

SUBSCRIPTIONS European Tool amp Mould Making is published 10 times per year

Annual subscription in Europe euro 7900 incl VAT (1 year) euro 15000 incl VAT (2 years)Readers outside Europe euro 9900 incl VAT (1 year) euro 18500 incl VAT (2 years)

Single copies euro 1100 incl VAT

Subscription inquiries back issues address changes send your request to European Tool amp Mould Makingby e-mail to etmmtool-moldmakingcom or by fax to +49 6122 51090

Circulation Audit Member of the Informationsgemeinschaft zur Feststellung der Verbreitung von Werbetraumlgern eV (IVW) Berlin

Printed at Koumlssinger AG wwwkoessingerde

Copyright copy 2011 ACCESS COMMUNICATIONS INC ALL RIGHTS RESERVED

OfficialMedia Partner of

ISTMA Europe

7

Industry News

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

More visitors an even more interna-tional character and the best pos-sible accompanying programme of events elucidating current industry trends are the objectives of the orga-nizer and sponsors of AMB 2012 the International Exhibition for Metal-working Messe Stuttgart along with the Precision Tools Association of the VDMA (German Engineering Federa-tion) the VDMA Software Association and the VDW (German Machine Tool Buildersrsquo Association) want the show

handling apparatus Nearly a quar-ter of the exhibiting companies last year came from a record 80 coun-tries outside Germany and the pro-portion of foreign visitors increased between 2008 and 2010 from 7 to 11 Messe Stuttgart is focusing on increasing the eventrsquos international-ization further in 2012

Organizer of AMB 2012 Building on Success

raquo AMB 2012Stuttgart Germanywwwmesse-stuttgartde

which takes place September 18ndash22 in Stuttgart to surpass the signal suc-cess of the 2010 edition which fully satisfied the more than 1300 exhibi-tors and 86000 visitors

Fully booked halls are expected again in 2012 with the exhibition occupying an area of 105000 m2 Exhibitors will be displaying main-ly milling machines lathes cutting tools chucking tools CADCAMCAE and other software grinding machines and workpiece- and tool-

RosMould 2011 Comes to Moscow in June

RosMould 2011 the special-ized international exhibition for moulds die moulds and stamps taking place June 15ndash17 at the Crocus Expo in Moscow is as the organizer Expo-M-Group Ltd says the only such trade fair offered within the post-Soviet Russian ter-ritory The show has relevance for all manufacturing sectors

Also notes Expo-M-Group the global economic crisis is becom-ing less of a factor in the field of moulds dies and stamps as pro-duction picks up in Russia and elsewhere Investors in produc-tion equipment are ready again to spend on the sort of technological advances in design and engineer-ing simulation and prototyping production software tooling die moulds and stamps materials metalworking and forming equip-ment automation and QC sys-tems and standard components RosMould exhibitors present

RosMould 2011 is co-located with RosPlast the specialized exhibition for plastics technology and products

raquo RosMould 2011Moscow Russiawwwrosmouldcom

Watch Mastercam circle the globe at wwwtinyurlcommcglobe

8

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

With more than 15000 installed seats of its CAM software world-wide and a global network of more than 120 resellers in 50 countries SolidCAM GmbH has enjoyed great success The companyrsquos biggest mar-ket is Germany where some 2000 users are working

The CAM Competence Centre of

Husky Injection Molding Systems is expected to complete its acquisition of KTW a global manufacturer of clo-sure moulds that is headquartered in Waidhofen Austria in May 2011 The purchase represents a logical next step in a 14-year relationship between the companies

Husky and KTW have worked together to develop closure manu-facturing systems that enhance cus-tomersrsquo productivity while eliminat-ing waste and improving part quality explains John Galt Husky president and CEO But even closer collaboration was seen to be necessary for meeting

DPS Software GmbH has contributed nicely to this success in Germany as was acknowledged during a recent ceremony at SolidCAM headquarters in Schramberg There Stephan Ter-horst the software developerrsquos Ger-man marketing director presented the award for most successful world-wide SolidCAM reseller in 2010 to Joumlrg

Rudig (at right in photo) the manager of the DPS CAM Competence Centre and his staff of 13

DPS Software has 13 subsidiaries and 145 employees making it one of the biggest product lifecycle manage-ment project partners in Germany Austria and Switzerland An important growth engine for the companyrsquos prow-ess in integrated CAD CAE CAM PDM and ERP software solutions and related services is its CAM Compe-tence Centre Since the time the cen-tre was founded in 2000 the com-petence centre team has provided an integrated SolidWorksSolidCAM CADCAM solution for more than 1500 CNC machines As Joumlrg Rudig points out a key part of DPSrsquos service offering is the provision of customer-oriented training programmes to sup-port its CADCAM products

increasingly high expectations partic-ularly in developing the core elements of closure systems

Husky will offer KTW-branded clo-sure moulds as part of its line of fully integrated turnkey systems when the deal is concluded making it the clo-sure industryrsquos only provider of com-plete injection moulding systems including the mould machine hot runner and temperature controller as well as consulting and after-sales ser-vices KTW managing directors Anja and Claus Ziegler will continue to be involved at the top management level

KTW operations in Austria the Czech Republic and Germany are to become Huskyrsquos closure mould devel-opment and manufacturing cen-tres of excellence In addition Husky plans to initiate a strategic review of KTWrsquos custom injection mould-ing division Injectoplast in order to ensure the divisionrsquos future success and avoid potential conflicts of inter-est with its own customers

SolidCAM Presents DPS Software with Global Best Reseller Award for 2010

raquo SolidCAM GmbHSchramberg Germanywwwsolidcamde

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Husky Solidifies Its Position in Closure-Mould Market through Acquisition of KTW

Molded to your needs

www3dscommoldandtooling

Mold amp ToolingBoost your efficiency and save time with a robust and innovative approach

CATIA Mold amp Tooling brings the extra added value of an integrated end-to-end solution From design and engineering to simulation and manufacturing take advantage of proven

optimized processes to satisfy the increasing expectations of your customers

ww

w3

dsc

om

copy

Das

saul

t Sy

stegravem

es 2

011

ndash A

ll ri

ghts

rese

rved

ndash C

ATI

A is

a re

gist

ered

tra

dem

ark

of D

assa

ult

Syst

egravemes

or

its

subs

idia

ries

in t

he U

S an

d

or o

ther

cou

ntri

es

10

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Industry News

New President for Sandvik Materials Technology

Mastercam for SolidWorks Wins Gold Partner Status

Peter Gossas president of Sandvik Materials Tech-nology for nine years will retire and leave the Sand-vik Group on May 31 2011 Jonas Gustavsson (pictured) currently president of the Wire and Heating Technol-ogy product area within Sandvik Materials Technol-ogy has been appointed as the business divisionrsquos new president He also becomes

a member of Sandvikrsquos group executive managementSandvik Materials Technology is the Sandvik business

area that supplies metalworking materials It occupies a position within the group equivalent to that of Sandvik Coromant the cutting-tools division

Gustavsson who earned a degree in mechanical engi-neering from Lulearing Technical University has acquired solid industry experience by holding senior positions within and outside Sandvik Says Olof Faxander president and CEO of Sandvik AB ldquoWith his broad background and proven ability

The Mastercam for SolidWorksreg software package developed by CNC Software Inc to support Solid-Worksreg 3D CAD software has been awarded Certified Gold Partner status by Dassault Systegravemes SolidWorks Corp Designers engineers and machinists use Mas-tercam for SolidWorks software to programme tool paths after designs have been finished in SolidWorks The tool paths are applied directly to the SolidWorks model in their native environment Thus users of Mastercam for SolidWorks and SolidWorks 2011 in combination can employ Mastercamreg CAM technolo-gy to create a machining programme without leaving the SolidWorks interface

ldquoWith our tool paths running directly in the Solid-Works environment our users will feel comfortable programming their parts just as if they were in stan-dard Mastercamrdquo explains CNC Software marketing manager Ben Mund ldquoThe beauty is that now they can run those tool paths inside of SolidWorks with-out the hassle of exporting files and handling the translationrdquo

The point of the cooperation as Nick Iwaskow SolidWorksrsquo manager of alliances points out is that ldquointegration between key product design applica-tions can shave precious time off of the develop-ment process and increase productivityrdquo Ultimately designers and engineers can improve their designs

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

raquo CNC Software IncTolland CT USAwwwmastercamcom

STRACK NORMAGmbH amp Co KGKoumlnigsberger Str 11D-58511 Luumldenscheid

Tailor - MadeSolutions

NEW

CENTRING ELEMENTSfree of play bull wear-free bull with needle rollers

Tel +49 (0) 2351 8701-0Fax +49 (0) 2351 8701-100wwwstrackdeinfostrackde

to successfully drive change Jonas Gustavsson has the right profile to lead Sandvik Materials Technologyrdquo

Faxander also acknowledges the achievements of Gos-sas noting that the outgoing president could take credit for moving the product programme increasingly toward high-value-added products improving manufacturing pro-cesses and stepping up product development

11

Industry News

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

phone +49 (0) 92529993-0

fax +49 (0) 92529993-33

vertriebrainer-knarrde

wwwrainer-knarrde

Visit us

hall 4 booth D62

- shaft without bulge

- head underneath and

head diameter ground

- height of head 0-003

- suitable as contour pin

- high temperature resistance

- ability for coating and nitration

- wide range of dimensions

Contact UK and Ireland

Gunther UK Limited

phone 01474879774

infogunthercouk

Contact Czech Republic

wwwrsmplastcz

ISO 90012008

certified

Innovative waved

baffle profile

- shorter cycle times

- improved cooling-effect

- swirl of the medium

- prolongable up to 625mm

- temperature resistant 200degC max

Protected

system

Reduce cycle times with the new generation of

cooling deflection baffles

Ejectors - outline pins

hardened approx 53 HRC

With 78 manufacturers suppliers and service providers from the addi-tive technologies sector having con-firmed their participation as exhibi-tors at EuroMold 2011 the trade fair for mould making and tooling design and application development is extending its claim to be the most important European marketplace for this growing industrial field also known as e-production Numerous market-leading innovators specializ-ing in additive manufacturing will be presenting themselves at the Frank-furt Exhibition Centre November 29 through December 2 particularly in Hall 11

The EuroMold organizer DEMAT GmbH has provided additional show-cases for the additive technologies sector through its offer of the uni-

versity researchndashbased special-focus show within a show ldquoe-Production for Everyonerdquo this year in its third edi-tion and the globally renowned Inter-national Wohlers Conference In 2011 the 13th Wohlers Conference will feature an emphasis on design in the production of additives

E-production experts think 2011 will be a year of strong growth driven by the release of pent-up demand for new product development technol-

ogies and services ldquoAs companies investigate additive manufacturing for the production of end-use prod-ucts a new level of technology adop-tion will unfoldrdquo says Terry Wohlers CEO of Wohlers Associates Inc

EuroMold 2011 presents the entire spectrum of additive technologies and their uses including 3D-printed products for industrial applications Among the top global companies dis-playing their latest materials tech-nologies and applications will be 3D Systems Alphacam Concept Laser EOS FIT Huntsman Materialise MTT Objet Realizer SLM Solutions Strata-sys and Z Corp

EuroMold 2011 Is Planned to Solidify Position As Premiere Additive Technologies Marketplace

raquo EuroMold 2011FrankfurtMain Germanywwweuromoldcom

EURO

MO

LD

12

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

In Sosnowiec Poland prepara-tions are in full swing for Toolex 2011 the International Machine Tools Tools and Processing Tech-nology Fair which is scheduled to take place October 5ndash7 at the Expo Silesia Exhibition Cen-tre This prestigious event for the metal-processing industry attracts more and more indus-try experts every year In 2010 more than 6000 professional and expert show visitors were very satisfied by what they found at the 167 exhibition stands showcasing over 350 companies from more than two dozen coun-tries around the world

Toolex always offers a compre-hensive presentation of machine tools specialized tools tech-nological equipment software and measuring and control instruments including world premieres of many machines and tools Last year in an exhibition area extending over more than 4000 m2 181 metal-processing machine tools on display were in full operation The venue is equipped to allow exhibitors to display large and

complex operating machines includ-ing entire assembly lines

The exhibition facility in Sosno wiec is situated in the heart of Polandrsquos most industrial region which is also an important scientific centre The area of Silesia and Zaglebie is home to a range of fast-growing industri-al sectors such as the automotive

aviation and mechanical engineer-ing industries among others Also the Czech Republic and Slovakia are nearby Transportation access to the venue is well developed

Expo Silesia Expects Toolex 2011 to Be Another Successful Metal-Processing Fair

raquo Toolex 2011Sosnowiec Polandwwwtoolexpl

MCH Swiss Exhibition (Basel) Ltd has handed over the organization and operation of Swisstech Europersquos Central Fair for the Subcontracting Industries to its wholly owned sub-sidiary Exhibit amp More AG The latter company now is in charge of Swiss-tech 2012 scheduled for November 20ndash23 2012 in Basel Exhibit amp More headquartered near Zuumlrich has been organizing specialist industrial fairs for more than 30 years

Swisstech is a key meeting point

The MCH Group assumed full con-trol of Exhibit amp More at the beginning of 2010 The managers of both trade fair organizing entities are convinced that the merger of their forces will make it possible to position Swisstech and Prodex in the market more effi-ciently and to steer a course toward a successful future

Swisstech Fair Henceforward in Hands of MCH Messe Basel Subsidiary Exhibit amp More

raquo Exhibit amp More AGFaumlllanden-Zuumlrich Switzerlandwwwexhibitandmorech

every two years for the subcontract-ing industry companies operating in the fields of procurement manu-facturing and production technolo-gy MCHmdashalso known as MCH Messe Baselmdashhas used Swisstech to high-light the synergies that exist between the mechanical engineering industry and the world of specialist suppliers It has also organized Prodex the spe-cialist exhibition for machine tools tools and production measurement in parallel with Swisstech since 2004

Who knocks PET bottles into shape

CorroPlastreg

ndash the ultimate steel forall-stainless mould sets

DEUTSCHE EDELSTAHLWERKE Obere Kaiserstr D-57078 Siegen Auestr 4 D-58452 Witten

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Industry News

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

Interactive Meusburger Catalogue Provides Free Standard Parts Calculation

Version 50 of the interactive CD catalogue issued by Meusburger the Austrian manufacturer of standard parts has many new features The catalogue software includes new products for mould making as well as the entire punching tool product range a recent addition to the Meusburger portfolio The company has prided itself on setting industry trends for digital catalogues and the advanced features in the latest CD version continue the customer-oriented tradition

The software is equipped with a mould assistant for injection moulding tools and a die-set assistant for punch-ing-tool construction Selecting various plates from a mod-ular system users can assemble mould tools and die sets with just a few clicks of the mouse The software then cal-culates all necessary accessories fully automatically and free of charge The CD catalogue includes 3D models of more than 46000 Meusburger products which are easily exported into all current CAD systems and as neutral data

By displaying individual prices for different customers the digital catalogue renders inquiries obsolete Also the integrated e-mail function makes ordering a faster and simpler process Useful search options and new group fil-ters (with pictures) help save time and effort in looking for products And finally an automatic update feature makes sure that users are working with the latest software and will not miss any newly introduced products

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo FIP Solution Plastique 2011Lyon Francewwwf-i-pcom

raquo Eberhard WerkzeugtechnologieNordheim Germanywwweberhardde

FIP 2011 Plastics Industry Exhibition Due in Lyon in May

Eberhard GmbH Enjoys a 28 Increase in Turnover in 2010

From May 24 to 27 the Rhocircne capital of Lyon will host FIP Solution Plastique 2011 the Plastics Industry Exhibition in France FIP is the only French trade show that brings all of the plastics industry players togeth-er in one place in this case the Lyon Eurexpo More than 500 exhibitors representing all aspects of the plas-tics industry will be on hand These include upstream suppliers of raw materials as well as producers or pro-viders of machines and equipment moulds and tools design services prototypes and models inspection technologies for quality control soft-ware and recycling technology Pro-cessors directly connected with final clients will be present in the area des-ignated FIPrsquoProjets

Because innovation is so important for companies wishing to stand out in

Gebruumlder Eberhard GmbH the par-ent company of the tool technology specialist Eberhard Werkzeugtech-nologie increased its turnover to just under euro90 million in 2010 a 28 rise Thus the company has managed to top the highest figure it had achieved before the period of economic crisis Meanwhile its staff increased by 10 last year to 440 employees

Eberhard GmbH manufactures stan-dard parts and accessories for tools in Nordheim and runs a specialized electrical retail outlet in Heilbronn as well as operating an additional tool technology production site in Thuringia and another electrical retail outlet in Saxony

Z 107101 Z 107105

The new universalneedle valvepermits the construction of compactmoulds and simplifies the integration of the needle valve systems in manyapplications

Unique flexibility in nozzle length and diameter

Can be used with all standard nozzles

Flexible valve pin strokeup to 7 mm

Available for 2 needle diameters (2 and 25 mm)

Flexible drive solutions Hydraulic internal or pneumatic external

No melt split in the diverting unit

Integration in stack and tandem moulds is possible

Minimum mounting space

HASCO Hasenclever GmbH+Co KGIm Wiesental 77 middot D-58513 LuumldenscheidTel +49 2351 957-0 middot Fax +49 2351 957-237E-mail infohascocom middot wwwhascocom

Together we shape your ideas

Improved colour change properties

the market FIP Solu-tion Plastique 2011 includes the Innova-tion Forum which offers a harmonized overview of recent industry develop-

ments Exhibitors in 15- to 20-minute speeches will unveil innovative solu-tions that resulted from advanced research and new technologies The trade fair also comprises a free con-ference programme and other edu-cational offerings to complement the Innovation Forum and FIPrsquoProjets

The 4th annual Caoutchouc Caucho Gomma international meeting of the rubber and polymer industries takes place at the same time as FIP Solution Plastique 2011 and also in the Lyon Eurexpo

The company benefited from the fact that it did not reduce its work-force in 2009 despite a significant decline in turnover In fact it made extensive investments and doubled the production area in Nordheim ldquoAfter all positive continuity is what sets down-to-earth family-owned companies apartrdquo says CEO Roland Eberhard Eberhard GmbH also expanded its vocational trainee pro-gramme and has signed contracts with a second generation of students at the Cooperative University

Industry News

16

Cover Story | Interview

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

A company with a strong pres-ence in Europe Meusburger

is a long-established specialist in the field of standard moulds In the past few years the Austrian enterprise has invested consider-able resources in expanding plant capacity in an effort to keep pace with its business growth Mean-while it introduced a completely new line of tool components to

enlarge an already bulging product catalogue

A strong position in the Euro-pean market is not alone enough for Meusburger Standard Moulds however The company founded a sales office in China in 2010 ETMM spoke with the companyrsquos managing director Guntram Meusburger son of the epony-mous founder about these and other aspects of Meusburgerrsquos present and future operations

ETMM Please give us a brief history of Meusburger GmbH How did the company start and how did it reach its present statureMeusburger ldquoConcentrating on our own strengthsrdquomdashthis slogan has been guiding Meusburger ever since 1964 The company started off as a one-man business and today employs 420 members of staff By continuously focusing on its own strengths clearly struc-tured processes the targeting of products to meet customer needs

and quality assurance Meusburg-er has become a European leader in the field of standard moulds which represents the companyrsquos main product line

Which industry sector is most impor-tant to your company and which sectors are you looking to develop furtherMeusburger stands for continu-ity and growthmdashand especially for high-quality products for the tool and mould making industry Last year we created space for some new things and we became very active in many other areas as well For example we prepared the introduction of a new field of businessmdashnamely punching tool

construction for which we have developed products We want to continue on this successful path in the coming year

We are particularly proud of our modular systemndashbased punch-ing-tool standard parts which are completely new However though these products are in fact new we have managed to adapt numerous well-known Meusburger advan-tages from our injection-mould-making range for use in construct-ing the punching tools

What recent or forthcoming new tech-nologies will bring your customers more value in the futureStress-relieved standard parts that is the obvious answer Playing a key role at the beginning of the process chain these components form a reliable foundation for high-quality moulds and tools The latest investment project of Meusburger has been additional furnaces with 120 tons of loading capacity per day With this invest-ment we increased the existing capacity by more than half

Stress-relieved standard parts in particular the parts for injec-tion moulds and punching dies offer many benefits to toolmak-ers We apply the stress-relieving

Concentrating on Strengths a Mould Industry Supplier GrowsMeusburger Standard Moulds has been successful for nearly half a century and its director suggests intends not to let up

ldquoMeusburger stands for continuity and growthmdashand especially for high-quality products for the tool and mould making industry We place great value on products that provide a clear added value for our customersrdquo

Managing Director Guntram Meusburger

wwwthebrightworldofmetalscom wwwgmtnde

One date ndash one place ndash four eventsMake the most of four high-calibre trade fairs ndash for foundry technology metallurgy thermo process technology and precision castings ndash in one place and with one entrance ticket

The industriesrsquo Number 1 worldwide multiple synergies connections and networks all in just one show visit Welcome to Duumlsseldorf

The Bright Worldof MetalsDuumlsseldorf Germany 28 June ndash 02 July 2011

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Interview

heat treatment to all grades of steel That is the best prerequisite for warp-free machining of parts

What do you consider to be Meusburgerrsquos most important product rangeManufacturing plates for injection moulding and punching tools clearly is our biggest strength in rela-tion to our competitors Meusburger uses the best raw materials and suppliers and we implement a programme of complete quality assurance through-out the production process

How important is research and development to Meus-burger Standard MouldsWe place great value on products that provide a clear added value for our customers Therefore we develop new products by working together with customers to fulfill not only their specific needs but also and especially the needs of the market generally

Is Meusburger GmbH active in AsiaIn 2010 we opened a new sales office in Wuxi China in Jiangsu Province The reason for that is that many of our customers have manufacturing operations in China and have expressed an inter-est in using standard products made by Meusburger there As a supplier of high-quality standard parts we naturally thought it was important for us to have an in-country sales office of our own

Incidentally from May 17 to May 20 this year Meusburger GmbH will be represented for the first time at the Chinaplas trade fair which is being held in the city of Guangzhou China We invite read-ers intending to visit that show to come see us at Stand D 41 in Hall 32

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

The investment of millions of euros in the Meusburger production facility in Wolfurt in recent years extended the companyrsquos capabilities For example new furnaces allow the standard parts manufacturer to produce stress-relieved components in greater volume

18

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Advanced series of customized hot runner systems a thoroughly innovative new solution

from DME has been designed to free mould makers from the limita-tions imposed by ldquohalf-

standardrdquo solutionsmdashthat is the use of standard

products to construct a special hot runner system

With the concept-products of the Advanced series the

moulder receives a fully cus-tomer-specific system tailored

to defined needs without any compromising that will perform

exactly as it should

This hot runner series was made possible by the development of sev-eral different nozzle tips with new openings These provide an opti-mal solution for every material and accommodate lateral-injection and multiple-gating requirements Within 24 hours of request DME will offer a quotation for a complex hot runner solution including a 3D drawing and a multiflow system if needed Deliv-ery of such a system can be expect-ed in 7 to 20 working days depend-ing on the complexity plus transport Expedited delivery also is available

raquo DME EuropeMechelen Belgiumwwwdmeeucom

Custom Hot Runners without Compromise Are Available via New System Solution

Rainer Knarr Vertriebs GmbH spe-cializes in the manufacture and sup-ply of standard and custom mould parts The company prides itself on including in its standards line mould accessories that other suppliers might offer only as specials

Beyond its extensive range of stan-dard components Rainer Knarr also provides custom mould components for tool and mould makers and injec-tion-moulders such as flat ejector pins with corner radius flat ejector pins with an extralong blade step-less sleeve ejectors pins that have a diamondlike-carbon (DLC) coating (photo) ejectors with an antitwist lock and many others All of these so-called standardized specials come in a wide range of stocked dimensions

The Rainer Knarr Group operates its own mould making division There-fore it well understands the needs and challenges of mould makers and

injection moulders The supplier sup-ports customers by offering a flexible ordering and deliv-ery servicemdashwith same-day shipping even for emergency orders received on Saturdaymdashan on-line shop and CAD data that is available for downloading

Always working on developing better solutions Rainer Knarr has recently launched several new product lines One is the huge XXL programme of flat ejector pins This line features pins in dimensions other than the well-known standard ones In addition it includes flat ejec-tors with corner radii and a DLC coat-ing flat ejectors with a long sheet and high-speed flat ejectors

Another line con-sists of patented hardened or nitrid-ed stepless ejector sleeves designed to facilitate reduction of the guide length

Also new from Rainer Knarr is a range of waved deflection baffles made of plastic which help ensure efficient balanced

mould cooling And the last highlight-ed recent introduction from the com-pany is a series of ejectors for outline pins that are made of hot-working steel hardened to 53 HRc for opti-mum machinability

Service-Oriented Supplier Provides Standard Mould Parts and Standardized Specials

raquo Rainer Knarr Vertriebs GmbHHelmbrechts Germanywwwrainer-knarrde

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Tuumlrk+Hillinger GmbH78532 Tuttlingen Germany

Tel +49 74 61 70 140 Fax +49 74 61 70 1410

infotuerk-hillingerde

wwwtuerk-hillingerde

since 1963

we are your best choice forheating elements

wide product range

large repertory of stock types

customer-specific executions

modern rational manufacturing methods

over 30000 heating elements daily

certified according to DIN ISO 90012000

high life span

500 qualified employees

over 240 patent applications

made in Germany

June 2011The focus of the Cover Story in the next issue of ETMM is Machining Equipment This section will include an overview article short Product Focus articles and a Quick Sourcing Grid of equipment suppliers serving the tool and mould making industry

The June issue also offers bull A Special Report focusing on mould making in Russia and a

EuroMold perspective on the RosMould exhibitionbull A Technology section focus on cutting tools and machining

accessories for tool and mould makersbull The Summer 2011 issue of EDM Europe

NEXT ISSUE

Volume XIII | Issue 4 | May 2011

Case Study 38Compact 3D Printer Expands Development Firmrsquos Horizons

Products amp Services 40Recently introduced equipment and services from all over

ISTMA 49Directory of ISTMA Europe Member Associations

Company Index 50A listing of the industry suppliers who supported this issue with articles and advertisements

TRU

MPF

GRO

UP

Table of Contents

VOLUME XIII NUMBER 4 MAY 2011

EUROPEAN TOOL amp MOULD MAKINGPublished by SellersMedia

P U B L I S H E R E D I T O R - I N - C H I E F

Douglas Sellersdsellerssellersmediacom

SELLERSMEDIAOtto-von-Guericke-Ring 3A 65205 Wiesbaden Germany

Tel +49 6122 95590 bull Fax +49 6122 51090infoetmm-onlinecomwwwetmm-onlinecom

P R O D U C T I O N C I R C U L AT I O N amp I N F O R M AT I O N S E R V I C E S

Briggette Jayabjayasellersmediacom

Melanie Rosselmrosselsellersmediacom

G R A P H I C D E S I G N E R S

Jason Sellersjsellerssellersmediacom

Law Wai Manlwmsellersmediacom

I N F O R M AT I O N T E C H N O L O G Y S P E C I A L I S T

Markus Muumlllermmuellersellersmediacom

S A L E S M A N A G E R

Britta Sollowaybsollowaysellersmediacom

A D V E R T I S I N G S A L E S F R A N C E

Evelyne Gisselbrecht33 Rue du Puy-de-Docircme 63370 Lempdes France

Tel +33 473 619557 bull Fax +33 473 619661egisselbrechtsellersmediacom

R E P R E S E N TAT I V E A G E N T F O R TA I WA N C H I N A amp H O N G KO N G

Robert Yu Worldwide Services Co Ltd11F-B No 540 Wen Hsin Road Section 1 Taichung 408 Taiwan

Tel +886 4 23251784 bull Fax +886 4 23252967saleswwstaiwancom

N O R T H A M E R I C A N O F F I C E30765 Pacific Coast Highway PMB 351

Malibu CA 90265-3643 USATel +1 805 744-7924 bull Fax +1 310 507-2032

usofficetool-moldmakingcom

B U S I N E S S M A N A G E R

MiSook Musselmanmmusselmantool-moldmakingcom

EDITORIAL CONTRIBUTIONS Productservice information bulletins and press releases should be submitted in English and should be accompanied by a colour photograph or transparency The publishers assume no responsibility for return of artwork photographs or manuscripts NOTICE Every precaution is taken to ensure accuracy of contents however the publishers cannot accept responsibility for the correctness of the information supplied or advertised or for any opinion expressed herein

SUBSCRIPTIONS European Tool amp Mould Making is published 10 times per year

Annual subscription in Europe euro 7900 incl VAT (1 year) euro 15000 incl VAT (2 years)Readers outside Europe euro 9900 incl VAT (1 year) euro 18500 incl VAT (2 years)

Single copies euro 1100 incl VAT

Subscription inquiries back issues address changes send your request to European Tool amp Mould Makingby e-mail to etmmtool-moldmakingcom or by fax to +49 6122 51090

Circulation Audit Member of the Informationsgemeinschaft zur Feststellung der Verbreitung von Werbetraumlgern eV (IVW) Berlin

Printed at Koumlssinger AG wwwkoessingerde

Copyright copy 2011 ACCESS COMMUNICATIONS INC ALL RIGHTS RESERVED

OfficialMedia Partner of

ISTMA Europe

7

Industry News

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

More visitors an even more interna-tional character and the best pos-sible accompanying programme of events elucidating current industry trends are the objectives of the orga-nizer and sponsors of AMB 2012 the International Exhibition for Metal-working Messe Stuttgart along with the Precision Tools Association of the VDMA (German Engineering Federa-tion) the VDMA Software Association and the VDW (German Machine Tool Buildersrsquo Association) want the show

handling apparatus Nearly a quar-ter of the exhibiting companies last year came from a record 80 coun-tries outside Germany and the pro-portion of foreign visitors increased between 2008 and 2010 from 7 to 11 Messe Stuttgart is focusing on increasing the eventrsquos international-ization further in 2012

Organizer of AMB 2012 Building on Success

raquo AMB 2012Stuttgart Germanywwwmesse-stuttgartde

which takes place September 18ndash22 in Stuttgart to surpass the signal suc-cess of the 2010 edition which fully satisfied the more than 1300 exhibi-tors and 86000 visitors

Fully booked halls are expected again in 2012 with the exhibition occupying an area of 105000 m2 Exhibitors will be displaying main-ly milling machines lathes cutting tools chucking tools CADCAMCAE and other software grinding machines and workpiece- and tool-

RosMould 2011 Comes to Moscow in June

RosMould 2011 the special-ized international exhibition for moulds die moulds and stamps taking place June 15ndash17 at the Crocus Expo in Moscow is as the organizer Expo-M-Group Ltd says the only such trade fair offered within the post-Soviet Russian ter-ritory The show has relevance for all manufacturing sectors

Also notes Expo-M-Group the global economic crisis is becom-ing less of a factor in the field of moulds dies and stamps as pro-duction picks up in Russia and elsewhere Investors in produc-tion equipment are ready again to spend on the sort of technological advances in design and engineer-ing simulation and prototyping production software tooling die moulds and stamps materials metalworking and forming equip-ment automation and QC sys-tems and standard components RosMould exhibitors present

RosMould 2011 is co-located with RosPlast the specialized exhibition for plastics technology and products

raquo RosMould 2011Moscow Russiawwwrosmouldcom

Watch Mastercam circle the globe at wwwtinyurlcommcglobe

8

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

With more than 15000 installed seats of its CAM software world-wide and a global network of more than 120 resellers in 50 countries SolidCAM GmbH has enjoyed great success The companyrsquos biggest mar-ket is Germany where some 2000 users are working

The CAM Competence Centre of

Husky Injection Molding Systems is expected to complete its acquisition of KTW a global manufacturer of clo-sure moulds that is headquartered in Waidhofen Austria in May 2011 The purchase represents a logical next step in a 14-year relationship between the companies

Husky and KTW have worked together to develop closure manu-facturing systems that enhance cus-tomersrsquo productivity while eliminat-ing waste and improving part quality explains John Galt Husky president and CEO But even closer collaboration was seen to be necessary for meeting

DPS Software GmbH has contributed nicely to this success in Germany as was acknowledged during a recent ceremony at SolidCAM headquarters in Schramberg There Stephan Ter-horst the software developerrsquos Ger-man marketing director presented the award for most successful world-wide SolidCAM reseller in 2010 to Joumlrg

Rudig (at right in photo) the manager of the DPS CAM Competence Centre and his staff of 13

DPS Software has 13 subsidiaries and 145 employees making it one of the biggest product lifecycle manage-ment project partners in Germany Austria and Switzerland An important growth engine for the companyrsquos prow-ess in integrated CAD CAE CAM PDM and ERP software solutions and related services is its CAM Compe-tence Centre Since the time the cen-tre was founded in 2000 the com-petence centre team has provided an integrated SolidWorksSolidCAM CADCAM solution for more than 1500 CNC machines As Joumlrg Rudig points out a key part of DPSrsquos service offering is the provision of customer-oriented training programmes to sup-port its CADCAM products

increasingly high expectations partic-ularly in developing the core elements of closure systems

Husky will offer KTW-branded clo-sure moulds as part of its line of fully integrated turnkey systems when the deal is concluded making it the clo-sure industryrsquos only provider of com-plete injection moulding systems including the mould machine hot runner and temperature controller as well as consulting and after-sales ser-vices KTW managing directors Anja and Claus Ziegler will continue to be involved at the top management level

KTW operations in Austria the Czech Republic and Germany are to become Huskyrsquos closure mould devel-opment and manufacturing cen-tres of excellence In addition Husky plans to initiate a strategic review of KTWrsquos custom injection mould-ing division Injectoplast in order to ensure the divisionrsquos future success and avoid potential conflicts of inter-est with its own customers

SolidCAM Presents DPS Software with Global Best Reseller Award for 2010

raquo SolidCAM GmbHSchramberg Germanywwwsolidcamde

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Husky Solidifies Its Position in Closure-Mould Market through Acquisition of KTW

Molded to your needs

www3dscommoldandtooling

Mold amp ToolingBoost your efficiency and save time with a robust and innovative approach

CATIA Mold amp Tooling brings the extra added value of an integrated end-to-end solution From design and engineering to simulation and manufacturing take advantage of proven

optimized processes to satisfy the increasing expectations of your customers

ww

w3

dsc

om

copy

Das

saul

t Sy

stegravem

es 2

011

ndash A

ll ri

ghts

rese

rved

ndash C

ATI

A is

a re

gist

ered

tra

dem

ark

of D

assa

ult

Syst

egravemes

or

its

subs

idia

ries

in t

he U

S an

d

or o

ther

cou

ntri

es

10

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Industry News

New President for Sandvik Materials Technology

Mastercam for SolidWorks Wins Gold Partner Status

Peter Gossas president of Sandvik Materials Tech-nology for nine years will retire and leave the Sand-vik Group on May 31 2011 Jonas Gustavsson (pictured) currently president of the Wire and Heating Technol-ogy product area within Sandvik Materials Technol-ogy has been appointed as the business divisionrsquos new president He also becomes

a member of Sandvikrsquos group executive managementSandvik Materials Technology is the Sandvik business

area that supplies metalworking materials It occupies a position within the group equivalent to that of Sandvik Coromant the cutting-tools division

Gustavsson who earned a degree in mechanical engi-neering from Lulearing Technical University has acquired solid industry experience by holding senior positions within and outside Sandvik Says Olof Faxander president and CEO of Sandvik AB ldquoWith his broad background and proven ability

The Mastercam for SolidWorksreg software package developed by CNC Software Inc to support Solid-Worksreg 3D CAD software has been awarded Certified Gold Partner status by Dassault Systegravemes SolidWorks Corp Designers engineers and machinists use Mas-tercam for SolidWorks software to programme tool paths after designs have been finished in SolidWorks The tool paths are applied directly to the SolidWorks model in their native environment Thus users of Mastercam for SolidWorks and SolidWorks 2011 in combination can employ Mastercamreg CAM technolo-gy to create a machining programme without leaving the SolidWorks interface

ldquoWith our tool paths running directly in the Solid-Works environment our users will feel comfortable programming their parts just as if they were in stan-dard Mastercamrdquo explains CNC Software marketing manager Ben Mund ldquoThe beauty is that now they can run those tool paths inside of SolidWorks with-out the hassle of exporting files and handling the translationrdquo

The point of the cooperation as Nick Iwaskow SolidWorksrsquo manager of alliances points out is that ldquointegration between key product design applica-tions can shave precious time off of the develop-ment process and increase productivityrdquo Ultimately designers and engineers can improve their designs

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

raquo CNC Software IncTolland CT USAwwwmastercamcom

STRACK NORMAGmbH amp Co KGKoumlnigsberger Str 11D-58511 Luumldenscheid

Tailor - MadeSolutions

NEW

CENTRING ELEMENTSfree of play bull wear-free bull with needle rollers

Tel +49 (0) 2351 8701-0Fax +49 (0) 2351 8701-100wwwstrackdeinfostrackde

to successfully drive change Jonas Gustavsson has the right profile to lead Sandvik Materials Technologyrdquo

Faxander also acknowledges the achievements of Gos-sas noting that the outgoing president could take credit for moving the product programme increasingly toward high-value-added products improving manufacturing pro-cesses and stepping up product development

11

Industry News

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

phone +49 (0) 92529993-0

fax +49 (0) 92529993-33

vertriebrainer-knarrde

wwwrainer-knarrde

Visit us

hall 4 booth D62

- shaft without bulge

- head underneath and

head diameter ground

- height of head 0-003

- suitable as contour pin

- high temperature resistance

- ability for coating and nitration

- wide range of dimensions

Contact UK and Ireland

Gunther UK Limited

phone 01474879774

infogunthercouk

Contact Czech Republic

wwwrsmplastcz

ISO 90012008

certified

Innovative waved

baffle profile

- shorter cycle times

- improved cooling-effect

- swirl of the medium

- prolongable up to 625mm

- temperature resistant 200degC max

Protected

system

Reduce cycle times with the new generation of

cooling deflection baffles

Ejectors - outline pins

hardened approx 53 HRC

With 78 manufacturers suppliers and service providers from the addi-tive technologies sector having con-firmed their participation as exhibi-tors at EuroMold 2011 the trade fair for mould making and tooling design and application development is extending its claim to be the most important European marketplace for this growing industrial field also known as e-production Numerous market-leading innovators specializ-ing in additive manufacturing will be presenting themselves at the Frank-furt Exhibition Centre November 29 through December 2 particularly in Hall 11

The EuroMold organizer DEMAT GmbH has provided additional show-cases for the additive technologies sector through its offer of the uni-

versity researchndashbased special-focus show within a show ldquoe-Production for Everyonerdquo this year in its third edi-tion and the globally renowned Inter-national Wohlers Conference In 2011 the 13th Wohlers Conference will feature an emphasis on design in the production of additives

E-production experts think 2011 will be a year of strong growth driven by the release of pent-up demand for new product development technol-

ogies and services ldquoAs companies investigate additive manufacturing for the production of end-use prod-ucts a new level of technology adop-tion will unfoldrdquo says Terry Wohlers CEO of Wohlers Associates Inc

EuroMold 2011 presents the entire spectrum of additive technologies and their uses including 3D-printed products for industrial applications Among the top global companies dis-playing their latest materials tech-nologies and applications will be 3D Systems Alphacam Concept Laser EOS FIT Huntsman Materialise MTT Objet Realizer SLM Solutions Strata-sys and Z Corp

EuroMold 2011 Is Planned to Solidify Position As Premiere Additive Technologies Marketplace

raquo EuroMold 2011FrankfurtMain Germanywwweuromoldcom

EURO

MO

LD

12

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

In Sosnowiec Poland prepara-tions are in full swing for Toolex 2011 the International Machine Tools Tools and Processing Tech-nology Fair which is scheduled to take place October 5ndash7 at the Expo Silesia Exhibition Cen-tre This prestigious event for the metal-processing industry attracts more and more indus-try experts every year In 2010 more than 6000 professional and expert show visitors were very satisfied by what they found at the 167 exhibition stands showcasing over 350 companies from more than two dozen coun-tries around the world

Toolex always offers a compre-hensive presentation of machine tools specialized tools tech-nological equipment software and measuring and control instruments including world premieres of many machines and tools Last year in an exhibition area extending over more than 4000 m2 181 metal-processing machine tools on display were in full operation The venue is equipped to allow exhibitors to display large and

complex operating machines includ-ing entire assembly lines

The exhibition facility in Sosno wiec is situated in the heart of Polandrsquos most industrial region which is also an important scientific centre The area of Silesia and Zaglebie is home to a range of fast-growing industri-al sectors such as the automotive

aviation and mechanical engineer-ing industries among others Also the Czech Republic and Slovakia are nearby Transportation access to the venue is well developed

Expo Silesia Expects Toolex 2011 to Be Another Successful Metal-Processing Fair

raquo Toolex 2011Sosnowiec Polandwwwtoolexpl

MCH Swiss Exhibition (Basel) Ltd has handed over the organization and operation of Swisstech Europersquos Central Fair for the Subcontracting Industries to its wholly owned sub-sidiary Exhibit amp More AG The latter company now is in charge of Swiss-tech 2012 scheduled for November 20ndash23 2012 in Basel Exhibit amp More headquartered near Zuumlrich has been organizing specialist industrial fairs for more than 30 years

Swisstech is a key meeting point

The MCH Group assumed full con-trol of Exhibit amp More at the beginning of 2010 The managers of both trade fair organizing entities are convinced that the merger of their forces will make it possible to position Swisstech and Prodex in the market more effi-ciently and to steer a course toward a successful future

Swisstech Fair Henceforward in Hands of MCH Messe Basel Subsidiary Exhibit amp More

raquo Exhibit amp More AGFaumlllanden-Zuumlrich Switzerlandwwwexhibitandmorech

every two years for the subcontract-ing industry companies operating in the fields of procurement manu-facturing and production technolo-gy MCHmdashalso known as MCH Messe Baselmdashhas used Swisstech to high-light the synergies that exist between the mechanical engineering industry and the world of specialist suppliers It has also organized Prodex the spe-cialist exhibition for machine tools tools and production measurement in parallel with Swisstech since 2004

Who knocks PET bottles into shape

CorroPlastreg

ndash the ultimate steel forall-stainless mould sets

DEUTSCHE EDELSTAHLWERKE Obere Kaiserstr D-57078 Siegen Auestr 4 D-58452 Witten

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Industry News

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

Interactive Meusburger Catalogue Provides Free Standard Parts Calculation

Version 50 of the interactive CD catalogue issued by Meusburger the Austrian manufacturer of standard parts has many new features The catalogue software includes new products for mould making as well as the entire punching tool product range a recent addition to the Meusburger portfolio The company has prided itself on setting industry trends for digital catalogues and the advanced features in the latest CD version continue the customer-oriented tradition

The software is equipped with a mould assistant for injection moulding tools and a die-set assistant for punch-ing-tool construction Selecting various plates from a mod-ular system users can assemble mould tools and die sets with just a few clicks of the mouse The software then cal-culates all necessary accessories fully automatically and free of charge The CD catalogue includes 3D models of more than 46000 Meusburger products which are easily exported into all current CAD systems and as neutral data

By displaying individual prices for different customers the digital catalogue renders inquiries obsolete Also the integrated e-mail function makes ordering a faster and simpler process Useful search options and new group fil-ters (with pictures) help save time and effort in looking for products And finally an automatic update feature makes sure that users are working with the latest software and will not miss any newly introduced products

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo FIP Solution Plastique 2011Lyon Francewwwf-i-pcom

raquo Eberhard WerkzeugtechnologieNordheim Germanywwweberhardde

FIP 2011 Plastics Industry Exhibition Due in Lyon in May

Eberhard GmbH Enjoys a 28 Increase in Turnover in 2010

From May 24 to 27 the Rhocircne capital of Lyon will host FIP Solution Plastique 2011 the Plastics Industry Exhibition in France FIP is the only French trade show that brings all of the plastics industry players togeth-er in one place in this case the Lyon Eurexpo More than 500 exhibitors representing all aspects of the plas-tics industry will be on hand These include upstream suppliers of raw materials as well as producers or pro-viders of machines and equipment moulds and tools design services prototypes and models inspection technologies for quality control soft-ware and recycling technology Pro-cessors directly connected with final clients will be present in the area des-ignated FIPrsquoProjets

Because innovation is so important for companies wishing to stand out in

Gebruumlder Eberhard GmbH the par-ent company of the tool technology specialist Eberhard Werkzeugtech-nologie increased its turnover to just under euro90 million in 2010 a 28 rise Thus the company has managed to top the highest figure it had achieved before the period of economic crisis Meanwhile its staff increased by 10 last year to 440 employees

Eberhard GmbH manufactures stan-dard parts and accessories for tools in Nordheim and runs a specialized electrical retail outlet in Heilbronn as well as operating an additional tool technology production site in Thuringia and another electrical retail outlet in Saxony

Z 107101 Z 107105

The new universalneedle valvepermits the construction of compactmoulds and simplifies the integration of the needle valve systems in manyapplications

Unique flexibility in nozzle length and diameter

Can be used with all standard nozzles

Flexible valve pin strokeup to 7 mm

Available for 2 needle diameters (2 and 25 mm)

Flexible drive solutions Hydraulic internal or pneumatic external

No melt split in the diverting unit

Integration in stack and tandem moulds is possible

Minimum mounting space

HASCO Hasenclever GmbH+Co KGIm Wiesental 77 middot D-58513 LuumldenscheidTel +49 2351 957-0 middot Fax +49 2351 957-237E-mail infohascocom middot wwwhascocom

Together we shape your ideas

Improved colour change properties

the market FIP Solu-tion Plastique 2011 includes the Innova-tion Forum which offers a harmonized overview of recent industry develop-

ments Exhibitors in 15- to 20-minute speeches will unveil innovative solu-tions that resulted from advanced research and new technologies The trade fair also comprises a free con-ference programme and other edu-cational offerings to complement the Innovation Forum and FIPrsquoProjets

The 4th annual Caoutchouc Caucho Gomma international meeting of the rubber and polymer industries takes place at the same time as FIP Solution Plastique 2011 and also in the Lyon Eurexpo

The company benefited from the fact that it did not reduce its work-force in 2009 despite a significant decline in turnover In fact it made extensive investments and doubled the production area in Nordheim ldquoAfter all positive continuity is what sets down-to-earth family-owned companies apartrdquo says CEO Roland Eberhard Eberhard GmbH also expanded its vocational trainee pro-gramme and has signed contracts with a second generation of students at the Cooperative University

Industry News

16

Cover Story | Interview

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

A company with a strong pres-ence in Europe Meusburger

is a long-established specialist in the field of standard moulds In the past few years the Austrian enterprise has invested consider-able resources in expanding plant capacity in an effort to keep pace with its business growth Mean-while it introduced a completely new line of tool components to

enlarge an already bulging product catalogue

A strong position in the Euro-pean market is not alone enough for Meusburger Standard Moulds however The company founded a sales office in China in 2010 ETMM spoke with the companyrsquos managing director Guntram Meusburger son of the epony-mous founder about these and other aspects of Meusburgerrsquos present and future operations

ETMM Please give us a brief history of Meusburger GmbH How did the company start and how did it reach its present statureMeusburger ldquoConcentrating on our own strengthsrdquomdashthis slogan has been guiding Meusburger ever since 1964 The company started off as a one-man business and today employs 420 members of staff By continuously focusing on its own strengths clearly struc-tured processes the targeting of products to meet customer needs

and quality assurance Meusburg-er has become a European leader in the field of standard moulds which represents the companyrsquos main product line

Which industry sector is most impor-tant to your company and which sectors are you looking to develop furtherMeusburger stands for continu-ity and growthmdashand especially for high-quality products for the tool and mould making industry Last year we created space for some new things and we became very active in many other areas as well For example we prepared the introduction of a new field of businessmdashnamely punching tool

construction for which we have developed products We want to continue on this successful path in the coming year

We are particularly proud of our modular systemndashbased punch-ing-tool standard parts which are completely new However though these products are in fact new we have managed to adapt numerous well-known Meusburger advan-tages from our injection-mould-making range for use in construct-ing the punching tools

What recent or forthcoming new tech-nologies will bring your customers more value in the futureStress-relieved standard parts that is the obvious answer Playing a key role at the beginning of the process chain these components form a reliable foundation for high-quality moulds and tools The latest investment project of Meusburger has been additional furnaces with 120 tons of loading capacity per day With this invest-ment we increased the existing capacity by more than half

Stress-relieved standard parts in particular the parts for injec-tion moulds and punching dies offer many benefits to toolmak-ers We apply the stress-relieving

Concentrating on Strengths a Mould Industry Supplier GrowsMeusburger Standard Moulds has been successful for nearly half a century and its director suggests intends not to let up

ldquoMeusburger stands for continuity and growthmdashand especially for high-quality products for the tool and mould making industry We place great value on products that provide a clear added value for our customersrdquo

Managing Director Guntram Meusburger

wwwthebrightworldofmetalscom wwwgmtnde

One date ndash one place ndash four eventsMake the most of four high-calibre trade fairs ndash for foundry technology metallurgy thermo process technology and precision castings ndash in one place and with one entrance ticket

The industriesrsquo Number 1 worldwide multiple synergies connections and networks all in just one show visit Welcome to Duumlsseldorf

The Bright Worldof MetalsDuumlsseldorf Germany 28 June ndash 02 July 2011

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Interview

heat treatment to all grades of steel That is the best prerequisite for warp-free machining of parts

What do you consider to be Meusburgerrsquos most important product rangeManufacturing plates for injection moulding and punching tools clearly is our biggest strength in rela-tion to our competitors Meusburger uses the best raw materials and suppliers and we implement a programme of complete quality assurance through-out the production process

How important is research and development to Meus-burger Standard MouldsWe place great value on products that provide a clear added value for our customers Therefore we develop new products by working together with customers to fulfill not only their specific needs but also and especially the needs of the market generally

Is Meusburger GmbH active in AsiaIn 2010 we opened a new sales office in Wuxi China in Jiangsu Province The reason for that is that many of our customers have manufacturing operations in China and have expressed an inter-est in using standard products made by Meusburger there As a supplier of high-quality standard parts we naturally thought it was important for us to have an in-country sales office of our own

Incidentally from May 17 to May 20 this year Meusburger GmbH will be represented for the first time at the Chinaplas trade fair which is being held in the city of Guangzhou China We invite read-ers intending to visit that show to come see us at Stand D 41 in Hall 32

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

The investment of millions of euros in the Meusburger production facility in Wolfurt in recent years extended the companyrsquos capabilities For example new furnaces allow the standard parts manufacturer to produce stress-relieved components in greater volume

18

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Advanced series of customized hot runner systems a thoroughly innovative new solution

from DME has been designed to free mould makers from the limita-tions imposed by ldquohalf-

standardrdquo solutionsmdashthat is the use of standard

products to construct a special hot runner system

With the concept-products of the Advanced series the

moulder receives a fully cus-tomer-specific system tailored

to defined needs without any compromising that will perform

exactly as it should

This hot runner series was made possible by the development of sev-eral different nozzle tips with new openings These provide an opti-mal solution for every material and accommodate lateral-injection and multiple-gating requirements Within 24 hours of request DME will offer a quotation for a complex hot runner solution including a 3D drawing and a multiflow system if needed Deliv-ery of such a system can be expect-ed in 7 to 20 working days depend-ing on the complexity plus transport Expedited delivery also is available

raquo DME EuropeMechelen Belgiumwwwdmeeucom

Custom Hot Runners without Compromise Are Available via New System Solution

Rainer Knarr Vertriebs GmbH spe-cializes in the manufacture and sup-ply of standard and custom mould parts The company prides itself on including in its standards line mould accessories that other suppliers might offer only as specials

Beyond its extensive range of stan-dard components Rainer Knarr also provides custom mould components for tool and mould makers and injec-tion-moulders such as flat ejector pins with corner radius flat ejector pins with an extralong blade step-less sleeve ejectors pins that have a diamondlike-carbon (DLC) coating (photo) ejectors with an antitwist lock and many others All of these so-called standardized specials come in a wide range of stocked dimensions

The Rainer Knarr Group operates its own mould making division There-fore it well understands the needs and challenges of mould makers and

injection moulders The supplier sup-ports customers by offering a flexible ordering and deliv-ery servicemdashwith same-day shipping even for emergency orders received on Saturdaymdashan on-line shop and CAD data that is available for downloading

Always working on developing better solutions Rainer Knarr has recently launched several new product lines One is the huge XXL programme of flat ejector pins This line features pins in dimensions other than the well-known standard ones In addition it includes flat ejec-tors with corner radii and a DLC coat-ing flat ejectors with a long sheet and high-speed flat ejectors

Another line con-sists of patented hardened or nitrid-ed stepless ejector sleeves designed to facilitate reduction of the guide length

Also new from Rainer Knarr is a range of waved deflection baffles made of plastic which help ensure efficient balanced

mould cooling And the last highlight-ed recent introduction from the com-pany is a series of ejectors for outline pins that are made of hot-working steel hardened to 53 HRc for opti-mum machinability

Service-Oriented Supplier Provides Standard Mould Parts and Standardized Specials

raquo Rainer Knarr Vertriebs GmbHHelmbrechts Germanywwwrainer-knarrde

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

VOLUME XIII NUMBER 4 MAY 2011

EUROPEAN TOOL amp MOULD MAKINGPublished by SellersMedia

P U B L I S H E R E D I T O R - I N - C H I E F

Douglas Sellersdsellerssellersmediacom

SELLERSMEDIAOtto-von-Guericke-Ring 3A 65205 Wiesbaden Germany

Tel +49 6122 95590 bull Fax +49 6122 51090infoetmm-onlinecomwwwetmm-onlinecom

P R O D U C T I O N C I R C U L AT I O N amp I N F O R M AT I O N S E R V I C E S

Briggette Jayabjayasellersmediacom

Melanie Rosselmrosselsellersmediacom

G R A P H I C D E S I G N E R S

Jason Sellersjsellerssellersmediacom

Law Wai Manlwmsellersmediacom

I N F O R M AT I O N T E C H N O L O G Y S P E C I A L I S T

Markus Muumlllermmuellersellersmediacom

S A L E S M A N A G E R

Britta Sollowaybsollowaysellersmediacom

A D V E R T I S I N G S A L E S F R A N C E

Evelyne Gisselbrecht33 Rue du Puy-de-Docircme 63370 Lempdes France

Tel +33 473 619557 bull Fax +33 473 619661egisselbrechtsellersmediacom

R E P R E S E N TAT I V E A G E N T F O R TA I WA N C H I N A amp H O N G KO N G

Robert Yu Worldwide Services Co Ltd11F-B No 540 Wen Hsin Road Section 1 Taichung 408 Taiwan

Tel +886 4 23251784 bull Fax +886 4 23252967saleswwstaiwancom

N O R T H A M E R I C A N O F F I C E30765 Pacific Coast Highway PMB 351

Malibu CA 90265-3643 USATel +1 805 744-7924 bull Fax +1 310 507-2032

usofficetool-moldmakingcom

B U S I N E S S M A N A G E R

MiSook Musselmanmmusselmantool-moldmakingcom

EDITORIAL CONTRIBUTIONS Productservice information bulletins and press releases should be submitted in English and should be accompanied by a colour photograph or transparency The publishers assume no responsibility for return of artwork photographs or manuscripts NOTICE Every precaution is taken to ensure accuracy of contents however the publishers cannot accept responsibility for the correctness of the information supplied or advertised or for any opinion expressed herein

SUBSCRIPTIONS European Tool amp Mould Making is published 10 times per year

Annual subscription in Europe euro 7900 incl VAT (1 year) euro 15000 incl VAT (2 years)Readers outside Europe euro 9900 incl VAT (1 year) euro 18500 incl VAT (2 years)

Single copies euro 1100 incl VAT

Subscription inquiries back issues address changes send your request to European Tool amp Mould Makingby e-mail to etmmtool-moldmakingcom or by fax to +49 6122 51090

Circulation Audit Member of the Informationsgemeinschaft zur Feststellung der Verbreitung von Werbetraumlgern eV (IVW) Berlin

Printed at Koumlssinger AG wwwkoessingerde

Copyright copy 2011 ACCESS COMMUNICATIONS INC ALL RIGHTS RESERVED

OfficialMedia Partner of

ISTMA Europe

7

Industry News

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

More visitors an even more interna-tional character and the best pos-sible accompanying programme of events elucidating current industry trends are the objectives of the orga-nizer and sponsors of AMB 2012 the International Exhibition for Metal-working Messe Stuttgart along with the Precision Tools Association of the VDMA (German Engineering Federa-tion) the VDMA Software Association and the VDW (German Machine Tool Buildersrsquo Association) want the show

handling apparatus Nearly a quar-ter of the exhibiting companies last year came from a record 80 coun-tries outside Germany and the pro-portion of foreign visitors increased between 2008 and 2010 from 7 to 11 Messe Stuttgart is focusing on increasing the eventrsquos international-ization further in 2012

Organizer of AMB 2012 Building on Success

raquo AMB 2012Stuttgart Germanywwwmesse-stuttgartde

which takes place September 18ndash22 in Stuttgart to surpass the signal suc-cess of the 2010 edition which fully satisfied the more than 1300 exhibi-tors and 86000 visitors

Fully booked halls are expected again in 2012 with the exhibition occupying an area of 105000 m2 Exhibitors will be displaying main-ly milling machines lathes cutting tools chucking tools CADCAMCAE and other software grinding machines and workpiece- and tool-

RosMould 2011 Comes to Moscow in June

RosMould 2011 the special-ized international exhibition for moulds die moulds and stamps taking place June 15ndash17 at the Crocus Expo in Moscow is as the organizer Expo-M-Group Ltd says the only such trade fair offered within the post-Soviet Russian ter-ritory The show has relevance for all manufacturing sectors

Also notes Expo-M-Group the global economic crisis is becom-ing less of a factor in the field of moulds dies and stamps as pro-duction picks up in Russia and elsewhere Investors in produc-tion equipment are ready again to spend on the sort of technological advances in design and engineer-ing simulation and prototyping production software tooling die moulds and stamps materials metalworking and forming equip-ment automation and QC sys-tems and standard components RosMould exhibitors present

RosMould 2011 is co-located with RosPlast the specialized exhibition for plastics technology and products

raquo RosMould 2011Moscow Russiawwwrosmouldcom

Watch Mastercam circle the globe at wwwtinyurlcommcglobe

8

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

With more than 15000 installed seats of its CAM software world-wide and a global network of more than 120 resellers in 50 countries SolidCAM GmbH has enjoyed great success The companyrsquos biggest mar-ket is Germany where some 2000 users are working

The CAM Competence Centre of

Husky Injection Molding Systems is expected to complete its acquisition of KTW a global manufacturer of clo-sure moulds that is headquartered in Waidhofen Austria in May 2011 The purchase represents a logical next step in a 14-year relationship between the companies

Husky and KTW have worked together to develop closure manu-facturing systems that enhance cus-tomersrsquo productivity while eliminat-ing waste and improving part quality explains John Galt Husky president and CEO But even closer collaboration was seen to be necessary for meeting

DPS Software GmbH has contributed nicely to this success in Germany as was acknowledged during a recent ceremony at SolidCAM headquarters in Schramberg There Stephan Ter-horst the software developerrsquos Ger-man marketing director presented the award for most successful world-wide SolidCAM reseller in 2010 to Joumlrg

Rudig (at right in photo) the manager of the DPS CAM Competence Centre and his staff of 13

DPS Software has 13 subsidiaries and 145 employees making it one of the biggest product lifecycle manage-ment project partners in Germany Austria and Switzerland An important growth engine for the companyrsquos prow-ess in integrated CAD CAE CAM PDM and ERP software solutions and related services is its CAM Compe-tence Centre Since the time the cen-tre was founded in 2000 the com-petence centre team has provided an integrated SolidWorksSolidCAM CADCAM solution for more than 1500 CNC machines As Joumlrg Rudig points out a key part of DPSrsquos service offering is the provision of customer-oriented training programmes to sup-port its CADCAM products

increasingly high expectations partic-ularly in developing the core elements of closure systems

Husky will offer KTW-branded clo-sure moulds as part of its line of fully integrated turnkey systems when the deal is concluded making it the clo-sure industryrsquos only provider of com-plete injection moulding systems including the mould machine hot runner and temperature controller as well as consulting and after-sales ser-vices KTW managing directors Anja and Claus Ziegler will continue to be involved at the top management level

KTW operations in Austria the Czech Republic and Germany are to become Huskyrsquos closure mould devel-opment and manufacturing cen-tres of excellence In addition Husky plans to initiate a strategic review of KTWrsquos custom injection mould-ing division Injectoplast in order to ensure the divisionrsquos future success and avoid potential conflicts of inter-est with its own customers

SolidCAM Presents DPS Software with Global Best Reseller Award for 2010

raquo SolidCAM GmbHSchramberg Germanywwwsolidcamde

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Husky Solidifies Its Position in Closure-Mould Market through Acquisition of KTW

Molded to your needs

www3dscommoldandtooling

Mold amp ToolingBoost your efficiency and save time with a robust and innovative approach

CATIA Mold amp Tooling brings the extra added value of an integrated end-to-end solution From design and engineering to simulation and manufacturing take advantage of proven

optimized processes to satisfy the increasing expectations of your customers

ww

w3

dsc

om

copy

Das

saul

t Sy

stegravem

es 2

011

ndash A

ll ri

ghts

rese

rved

ndash C

ATI

A is

a re

gist

ered

tra

dem

ark

of D

assa

ult

Syst

egravemes

or

its

subs

idia

ries

in t

he U

S an

d

or o

ther

cou

ntri

es

10

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Industry News

New President for Sandvik Materials Technology

Mastercam for SolidWorks Wins Gold Partner Status

Peter Gossas president of Sandvik Materials Tech-nology for nine years will retire and leave the Sand-vik Group on May 31 2011 Jonas Gustavsson (pictured) currently president of the Wire and Heating Technol-ogy product area within Sandvik Materials Technol-ogy has been appointed as the business divisionrsquos new president He also becomes

a member of Sandvikrsquos group executive managementSandvik Materials Technology is the Sandvik business

area that supplies metalworking materials It occupies a position within the group equivalent to that of Sandvik Coromant the cutting-tools division

Gustavsson who earned a degree in mechanical engi-neering from Lulearing Technical University has acquired solid industry experience by holding senior positions within and outside Sandvik Says Olof Faxander president and CEO of Sandvik AB ldquoWith his broad background and proven ability

The Mastercam for SolidWorksreg software package developed by CNC Software Inc to support Solid-Worksreg 3D CAD software has been awarded Certified Gold Partner status by Dassault Systegravemes SolidWorks Corp Designers engineers and machinists use Mas-tercam for SolidWorks software to programme tool paths after designs have been finished in SolidWorks The tool paths are applied directly to the SolidWorks model in their native environment Thus users of Mastercam for SolidWorks and SolidWorks 2011 in combination can employ Mastercamreg CAM technolo-gy to create a machining programme without leaving the SolidWorks interface

ldquoWith our tool paths running directly in the Solid-Works environment our users will feel comfortable programming their parts just as if they were in stan-dard Mastercamrdquo explains CNC Software marketing manager Ben Mund ldquoThe beauty is that now they can run those tool paths inside of SolidWorks with-out the hassle of exporting files and handling the translationrdquo

The point of the cooperation as Nick Iwaskow SolidWorksrsquo manager of alliances points out is that ldquointegration between key product design applica-tions can shave precious time off of the develop-ment process and increase productivityrdquo Ultimately designers and engineers can improve their designs

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

raquo CNC Software IncTolland CT USAwwwmastercamcom

STRACK NORMAGmbH amp Co KGKoumlnigsberger Str 11D-58511 Luumldenscheid

Tailor - MadeSolutions

NEW

CENTRING ELEMENTSfree of play bull wear-free bull with needle rollers

Tel +49 (0) 2351 8701-0Fax +49 (0) 2351 8701-100wwwstrackdeinfostrackde

to successfully drive change Jonas Gustavsson has the right profile to lead Sandvik Materials Technologyrdquo

Faxander also acknowledges the achievements of Gos-sas noting that the outgoing president could take credit for moving the product programme increasingly toward high-value-added products improving manufacturing pro-cesses and stepping up product development

11

Industry News

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

phone +49 (0) 92529993-0

fax +49 (0) 92529993-33

vertriebrainer-knarrde

wwwrainer-knarrde

Visit us

hall 4 booth D62

- shaft without bulge

- head underneath and

head diameter ground

- height of head 0-003

- suitable as contour pin

- high temperature resistance

- ability for coating and nitration

- wide range of dimensions

Contact UK and Ireland

Gunther UK Limited

phone 01474879774

infogunthercouk

Contact Czech Republic

wwwrsmplastcz

ISO 90012008

certified

Innovative waved

baffle profile

- shorter cycle times

- improved cooling-effect

- swirl of the medium

- prolongable up to 625mm

- temperature resistant 200degC max

Protected

system

Reduce cycle times with the new generation of

cooling deflection baffles

Ejectors - outline pins

hardened approx 53 HRC

With 78 manufacturers suppliers and service providers from the addi-tive technologies sector having con-firmed their participation as exhibi-tors at EuroMold 2011 the trade fair for mould making and tooling design and application development is extending its claim to be the most important European marketplace for this growing industrial field also known as e-production Numerous market-leading innovators specializ-ing in additive manufacturing will be presenting themselves at the Frank-furt Exhibition Centre November 29 through December 2 particularly in Hall 11

The EuroMold organizer DEMAT GmbH has provided additional show-cases for the additive technologies sector through its offer of the uni-

versity researchndashbased special-focus show within a show ldquoe-Production for Everyonerdquo this year in its third edi-tion and the globally renowned Inter-national Wohlers Conference In 2011 the 13th Wohlers Conference will feature an emphasis on design in the production of additives

E-production experts think 2011 will be a year of strong growth driven by the release of pent-up demand for new product development technol-

ogies and services ldquoAs companies investigate additive manufacturing for the production of end-use prod-ucts a new level of technology adop-tion will unfoldrdquo says Terry Wohlers CEO of Wohlers Associates Inc

EuroMold 2011 presents the entire spectrum of additive technologies and their uses including 3D-printed products for industrial applications Among the top global companies dis-playing their latest materials tech-nologies and applications will be 3D Systems Alphacam Concept Laser EOS FIT Huntsman Materialise MTT Objet Realizer SLM Solutions Strata-sys and Z Corp

EuroMold 2011 Is Planned to Solidify Position As Premiere Additive Technologies Marketplace

raquo EuroMold 2011FrankfurtMain Germanywwweuromoldcom

EURO

MO

LD

12

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

In Sosnowiec Poland prepara-tions are in full swing for Toolex 2011 the International Machine Tools Tools and Processing Tech-nology Fair which is scheduled to take place October 5ndash7 at the Expo Silesia Exhibition Cen-tre This prestigious event for the metal-processing industry attracts more and more indus-try experts every year In 2010 more than 6000 professional and expert show visitors were very satisfied by what they found at the 167 exhibition stands showcasing over 350 companies from more than two dozen coun-tries around the world

Toolex always offers a compre-hensive presentation of machine tools specialized tools tech-nological equipment software and measuring and control instruments including world premieres of many machines and tools Last year in an exhibition area extending over more than 4000 m2 181 metal-processing machine tools on display were in full operation The venue is equipped to allow exhibitors to display large and

complex operating machines includ-ing entire assembly lines

The exhibition facility in Sosno wiec is situated in the heart of Polandrsquos most industrial region which is also an important scientific centre The area of Silesia and Zaglebie is home to a range of fast-growing industri-al sectors such as the automotive

aviation and mechanical engineer-ing industries among others Also the Czech Republic and Slovakia are nearby Transportation access to the venue is well developed

Expo Silesia Expects Toolex 2011 to Be Another Successful Metal-Processing Fair

raquo Toolex 2011Sosnowiec Polandwwwtoolexpl

MCH Swiss Exhibition (Basel) Ltd has handed over the organization and operation of Swisstech Europersquos Central Fair for the Subcontracting Industries to its wholly owned sub-sidiary Exhibit amp More AG The latter company now is in charge of Swiss-tech 2012 scheduled for November 20ndash23 2012 in Basel Exhibit amp More headquartered near Zuumlrich has been organizing specialist industrial fairs for more than 30 years

Swisstech is a key meeting point

The MCH Group assumed full con-trol of Exhibit amp More at the beginning of 2010 The managers of both trade fair organizing entities are convinced that the merger of their forces will make it possible to position Swisstech and Prodex in the market more effi-ciently and to steer a course toward a successful future

Swisstech Fair Henceforward in Hands of MCH Messe Basel Subsidiary Exhibit amp More

raquo Exhibit amp More AGFaumlllanden-Zuumlrich Switzerlandwwwexhibitandmorech

every two years for the subcontract-ing industry companies operating in the fields of procurement manu-facturing and production technolo-gy MCHmdashalso known as MCH Messe Baselmdashhas used Swisstech to high-light the synergies that exist between the mechanical engineering industry and the world of specialist suppliers It has also organized Prodex the spe-cialist exhibition for machine tools tools and production measurement in parallel with Swisstech since 2004

Who knocks PET bottles into shape

CorroPlastreg

ndash the ultimate steel forall-stainless mould sets

DEUTSCHE EDELSTAHLWERKE Obere Kaiserstr D-57078 Siegen Auestr 4 D-58452 Witten

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Industry News

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

Interactive Meusburger Catalogue Provides Free Standard Parts Calculation

Version 50 of the interactive CD catalogue issued by Meusburger the Austrian manufacturer of standard parts has many new features The catalogue software includes new products for mould making as well as the entire punching tool product range a recent addition to the Meusburger portfolio The company has prided itself on setting industry trends for digital catalogues and the advanced features in the latest CD version continue the customer-oriented tradition

The software is equipped with a mould assistant for injection moulding tools and a die-set assistant for punch-ing-tool construction Selecting various plates from a mod-ular system users can assemble mould tools and die sets with just a few clicks of the mouse The software then cal-culates all necessary accessories fully automatically and free of charge The CD catalogue includes 3D models of more than 46000 Meusburger products which are easily exported into all current CAD systems and as neutral data

By displaying individual prices for different customers the digital catalogue renders inquiries obsolete Also the integrated e-mail function makes ordering a faster and simpler process Useful search options and new group fil-ters (with pictures) help save time and effort in looking for products And finally an automatic update feature makes sure that users are working with the latest software and will not miss any newly introduced products

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo FIP Solution Plastique 2011Lyon Francewwwf-i-pcom

raquo Eberhard WerkzeugtechnologieNordheim Germanywwweberhardde

FIP 2011 Plastics Industry Exhibition Due in Lyon in May

Eberhard GmbH Enjoys a 28 Increase in Turnover in 2010

From May 24 to 27 the Rhocircne capital of Lyon will host FIP Solution Plastique 2011 the Plastics Industry Exhibition in France FIP is the only French trade show that brings all of the plastics industry players togeth-er in one place in this case the Lyon Eurexpo More than 500 exhibitors representing all aspects of the plas-tics industry will be on hand These include upstream suppliers of raw materials as well as producers or pro-viders of machines and equipment moulds and tools design services prototypes and models inspection technologies for quality control soft-ware and recycling technology Pro-cessors directly connected with final clients will be present in the area des-ignated FIPrsquoProjets

Because innovation is so important for companies wishing to stand out in

Gebruumlder Eberhard GmbH the par-ent company of the tool technology specialist Eberhard Werkzeugtech-nologie increased its turnover to just under euro90 million in 2010 a 28 rise Thus the company has managed to top the highest figure it had achieved before the period of economic crisis Meanwhile its staff increased by 10 last year to 440 employees

Eberhard GmbH manufactures stan-dard parts and accessories for tools in Nordheim and runs a specialized electrical retail outlet in Heilbronn as well as operating an additional tool technology production site in Thuringia and another electrical retail outlet in Saxony

Z 107101 Z 107105

The new universalneedle valvepermits the construction of compactmoulds and simplifies the integration of the needle valve systems in manyapplications

Unique flexibility in nozzle length and diameter

Can be used with all standard nozzles

Flexible valve pin strokeup to 7 mm

Available for 2 needle diameters (2 and 25 mm)

Flexible drive solutions Hydraulic internal or pneumatic external

No melt split in the diverting unit

Integration in stack and tandem moulds is possible

Minimum mounting space

HASCO Hasenclever GmbH+Co KGIm Wiesental 77 middot D-58513 LuumldenscheidTel +49 2351 957-0 middot Fax +49 2351 957-237E-mail infohascocom middot wwwhascocom

Together we shape your ideas

Improved colour change properties

the market FIP Solu-tion Plastique 2011 includes the Innova-tion Forum which offers a harmonized overview of recent industry develop-

ments Exhibitors in 15- to 20-minute speeches will unveil innovative solu-tions that resulted from advanced research and new technologies The trade fair also comprises a free con-ference programme and other edu-cational offerings to complement the Innovation Forum and FIPrsquoProjets

The 4th annual Caoutchouc Caucho Gomma international meeting of the rubber and polymer industries takes place at the same time as FIP Solution Plastique 2011 and also in the Lyon Eurexpo

The company benefited from the fact that it did not reduce its work-force in 2009 despite a significant decline in turnover In fact it made extensive investments and doubled the production area in Nordheim ldquoAfter all positive continuity is what sets down-to-earth family-owned companies apartrdquo says CEO Roland Eberhard Eberhard GmbH also expanded its vocational trainee pro-gramme and has signed contracts with a second generation of students at the Cooperative University

Industry News

16

Cover Story | Interview

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

A company with a strong pres-ence in Europe Meusburger

is a long-established specialist in the field of standard moulds In the past few years the Austrian enterprise has invested consider-able resources in expanding plant capacity in an effort to keep pace with its business growth Mean-while it introduced a completely new line of tool components to

enlarge an already bulging product catalogue

A strong position in the Euro-pean market is not alone enough for Meusburger Standard Moulds however The company founded a sales office in China in 2010 ETMM spoke with the companyrsquos managing director Guntram Meusburger son of the epony-mous founder about these and other aspects of Meusburgerrsquos present and future operations

ETMM Please give us a brief history of Meusburger GmbH How did the company start and how did it reach its present statureMeusburger ldquoConcentrating on our own strengthsrdquomdashthis slogan has been guiding Meusburger ever since 1964 The company started off as a one-man business and today employs 420 members of staff By continuously focusing on its own strengths clearly struc-tured processes the targeting of products to meet customer needs

and quality assurance Meusburg-er has become a European leader in the field of standard moulds which represents the companyrsquos main product line

Which industry sector is most impor-tant to your company and which sectors are you looking to develop furtherMeusburger stands for continu-ity and growthmdashand especially for high-quality products for the tool and mould making industry Last year we created space for some new things and we became very active in many other areas as well For example we prepared the introduction of a new field of businessmdashnamely punching tool

construction for which we have developed products We want to continue on this successful path in the coming year

We are particularly proud of our modular systemndashbased punch-ing-tool standard parts which are completely new However though these products are in fact new we have managed to adapt numerous well-known Meusburger advan-tages from our injection-mould-making range for use in construct-ing the punching tools

What recent or forthcoming new tech-nologies will bring your customers more value in the futureStress-relieved standard parts that is the obvious answer Playing a key role at the beginning of the process chain these components form a reliable foundation for high-quality moulds and tools The latest investment project of Meusburger has been additional furnaces with 120 tons of loading capacity per day With this invest-ment we increased the existing capacity by more than half

Stress-relieved standard parts in particular the parts for injec-tion moulds and punching dies offer many benefits to toolmak-ers We apply the stress-relieving

Concentrating on Strengths a Mould Industry Supplier GrowsMeusburger Standard Moulds has been successful for nearly half a century and its director suggests intends not to let up

ldquoMeusburger stands for continuity and growthmdashand especially for high-quality products for the tool and mould making industry We place great value on products that provide a clear added value for our customersrdquo

Managing Director Guntram Meusburger

wwwthebrightworldofmetalscom wwwgmtnde

One date ndash one place ndash four eventsMake the most of four high-calibre trade fairs ndash for foundry technology metallurgy thermo process technology and precision castings ndash in one place and with one entrance ticket

The industriesrsquo Number 1 worldwide multiple synergies connections and networks all in just one show visit Welcome to Duumlsseldorf

The Bright Worldof MetalsDuumlsseldorf Germany 28 June ndash 02 July 2011

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Interview

heat treatment to all grades of steel That is the best prerequisite for warp-free machining of parts

What do you consider to be Meusburgerrsquos most important product rangeManufacturing plates for injection moulding and punching tools clearly is our biggest strength in rela-tion to our competitors Meusburger uses the best raw materials and suppliers and we implement a programme of complete quality assurance through-out the production process

How important is research and development to Meus-burger Standard MouldsWe place great value on products that provide a clear added value for our customers Therefore we develop new products by working together with customers to fulfill not only their specific needs but also and especially the needs of the market generally

Is Meusburger GmbH active in AsiaIn 2010 we opened a new sales office in Wuxi China in Jiangsu Province The reason for that is that many of our customers have manufacturing operations in China and have expressed an inter-est in using standard products made by Meusburger there As a supplier of high-quality standard parts we naturally thought it was important for us to have an in-country sales office of our own

Incidentally from May 17 to May 20 this year Meusburger GmbH will be represented for the first time at the Chinaplas trade fair which is being held in the city of Guangzhou China We invite read-ers intending to visit that show to come see us at Stand D 41 in Hall 32

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

The investment of millions of euros in the Meusburger production facility in Wolfurt in recent years extended the companyrsquos capabilities For example new furnaces allow the standard parts manufacturer to produce stress-relieved components in greater volume

18

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Advanced series of customized hot runner systems a thoroughly innovative new solution

from DME has been designed to free mould makers from the limita-tions imposed by ldquohalf-

standardrdquo solutionsmdashthat is the use of standard

products to construct a special hot runner system

With the concept-products of the Advanced series the

moulder receives a fully cus-tomer-specific system tailored

to defined needs without any compromising that will perform

exactly as it should

This hot runner series was made possible by the development of sev-eral different nozzle tips with new openings These provide an opti-mal solution for every material and accommodate lateral-injection and multiple-gating requirements Within 24 hours of request DME will offer a quotation for a complex hot runner solution including a 3D drawing and a multiflow system if needed Deliv-ery of such a system can be expect-ed in 7 to 20 working days depend-ing on the complexity plus transport Expedited delivery also is available

raquo DME EuropeMechelen Belgiumwwwdmeeucom

Custom Hot Runners without Compromise Are Available via New System Solution

Rainer Knarr Vertriebs GmbH spe-cializes in the manufacture and sup-ply of standard and custom mould parts The company prides itself on including in its standards line mould accessories that other suppliers might offer only as specials

Beyond its extensive range of stan-dard components Rainer Knarr also provides custom mould components for tool and mould makers and injec-tion-moulders such as flat ejector pins with corner radius flat ejector pins with an extralong blade step-less sleeve ejectors pins that have a diamondlike-carbon (DLC) coating (photo) ejectors with an antitwist lock and many others All of these so-called standardized specials come in a wide range of stocked dimensions

The Rainer Knarr Group operates its own mould making division There-fore it well understands the needs and challenges of mould makers and

injection moulders The supplier sup-ports customers by offering a flexible ordering and deliv-ery servicemdashwith same-day shipping even for emergency orders received on Saturdaymdashan on-line shop and CAD data that is available for downloading

Always working on developing better solutions Rainer Knarr has recently launched several new product lines One is the huge XXL programme of flat ejector pins This line features pins in dimensions other than the well-known standard ones In addition it includes flat ejec-tors with corner radii and a DLC coat-ing flat ejectors with a long sheet and high-speed flat ejectors

Another line con-sists of patented hardened or nitrid-ed stepless ejector sleeves designed to facilitate reduction of the guide length

Also new from Rainer Knarr is a range of waved deflection baffles made of plastic which help ensure efficient balanced

mould cooling And the last highlight-ed recent introduction from the com-pany is a series of ejectors for outline pins that are made of hot-working steel hardened to 53 HRc for opti-mum machinability

Service-Oriented Supplier Provides Standard Mould Parts and Standardized Specials

raquo Rainer Knarr Vertriebs GmbHHelmbrechts Germanywwwrainer-knarrde

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

7

Industry News

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

More visitors an even more interna-tional character and the best pos-sible accompanying programme of events elucidating current industry trends are the objectives of the orga-nizer and sponsors of AMB 2012 the International Exhibition for Metal-working Messe Stuttgart along with the Precision Tools Association of the VDMA (German Engineering Federa-tion) the VDMA Software Association and the VDW (German Machine Tool Buildersrsquo Association) want the show

handling apparatus Nearly a quar-ter of the exhibiting companies last year came from a record 80 coun-tries outside Germany and the pro-portion of foreign visitors increased between 2008 and 2010 from 7 to 11 Messe Stuttgart is focusing on increasing the eventrsquos international-ization further in 2012

Organizer of AMB 2012 Building on Success

raquo AMB 2012Stuttgart Germanywwwmesse-stuttgartde

which takes place September 18ndash22 in Stuttgart to surpass the signal suc-cess of the 2010 edition which fully satisfied the more than 1300 exhibi-tors and 86000 visitors

Fully booked halls are expected again in 2012 with the exhibition occupying an area of 105000 m2 Exhibitors will be displaying main-ly milling machines lathes cutting tools chucking tools CADCAMCAE and other software grinding machines and workpiece- and tool-

RosMould 2011 Comes to Moscow in June

RosMould 2011 the special-ized international exhibition for moulds die moulds and stamps taking place June 15ndash17 at the Crocus Expo in Moscow is as the organizer Expo-M-Group Ltd says the only such trade fair offered within the post-Soviet Russian ter-ritory The show has relevance for all manufacturing sectors

Also notes Expo-M-Group the global economic crisis is becom-ing less of a factor in the field of moulds dies and stamps as pro-duction picks up in Russia and elsewhere Investors in produc-tion equipment are ready again to spend on the sort of technological advances in design and engineer-ing simulation and prototyping production software tooling die moulds and stamps materials metalworking and forming equip-ment automation and QC sys-tems and standard components RosMould exhibitors present

RosMould 2011 is co-located with RosPlast the specialized exhibition for plastics technology and products

raquo RosMould 2011Moscow Russiawwwrosmouldcom

Watch Mastercam circle the globe at wwwtinyurlcommcglobe

8

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

With more than 15000 installed seats of its CAM software world-wide and a global network of more than 120 resellers in 50 countries SolidCAM GmbH has enjoyed great success The companyrsquos biggest mar-ket is Germany where some 2000 users are working

The CAM Competence Centre of

Husky Injection Molding Systems is expected to complete its acquisition of KTW a global manufacturer of clo-sure moulds that is headquartered in Waidhofen Austria in May 2011 The purchase represents a logical next step in a 14-year relationship between the companies

Husky and KTW have worked together to develop closure manu-facturing systems that enhance cus-tomersrsquo productivity while eliminat-ing waste and improving part quality explains John Galt Husky president and CEO But even closer collaboration was seen to be necessary for meeting

DPS Software GmbH has contributed nicely to this success in Germany as was acknowledged during a recent ceremony at SolidCAM headquarters in Schramberg There Stephan Ter-horst the software developerrsquos Ger-man marketing director presented the award for most successful world-wide SolidCAM reseller in 2010 to Joumlrg

Rudig (at right in photo) the manager of the DPS CAM Competence Centre and his staff of 13

DPS Software has 13 subsidiaries and 145 employees making it one of the biggest product lifecycle manage-ment project partners in Germany Austria and Switzerland An important growth engine for the companyrsquos prow-ess in integrated CAD CAE CAM PDM and ERP software solutions and related services is its CAM Compe-tence Centre Since the time the cen-tre was founded in 2000 the com-petence centre team has provided an integrated SolidWorksSolidCAM CADCAM solution for more than 1500 CNC machines As Joumlrg Rudig points out a key part of DPSrsquos service offering is the provision of customer-oriented training programmes to sup-port its CADCAM products

increasingly high expectations partic-ularly in developing the core elements of closure systems

Husky will offer KTW-branded clo-sure moulds as part of its line of fully integrated turnkey systems when the deal is concluded making it the clo-sure industryrsquos only provider of com-plete injection moulding systems including the mould machine hot runner and temperature controller as well as consulting and after-sales ser-vices KTW managing directors Anja and Claus Ziegler will continue to be involved at the top management level

KTW operations in Austria the Czech Republic and Germany are to become Huskyrsquos closure mould devel-opment and manufacturing cen-tres of excellence In addition Husky plans to initiate a strategic review of KTWrsquos custom injection mould-ing division Injectoplast in order to ensure the divisionrsquos future success and avoid potential conflicts of inter-est with its own customers

SolidCAM Presents DPS Software with Global Best Reseller Award for 2010

raquo SolidCAM GmbHSchramberg Germanywwwsolidcamde

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Husky Solidifies Its Position in Closure-Mould Market through Acquisition of KTW

Molded to your needs

www3dscommoldandtooling

Mold amp ToolingBoost your efficiency and save time with a robust and innovative approach

CATIA Mold amp Tooling brings the extra added value of an integrated end-to-end solution From design and engineering to simulation and manufacturing take advantage of proven

optimized processes to satisfy the increasing expectations of your customers

ww

w3

dsc

om

copy

Das

saul

t Sy

stegravem

es 2

011

ndash A

ll ri

ghts

rese

rved

ndash C

ATI

A is

a re

gist

ered

tra

dem

ark

of D

assa

ult

Syst

egravemes

or

its

subs

idia

ries

in t

he U

S an

d

or o

ther

cou

ntri

es

10

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Industry News

New President for Sandvik Materials Technology

Mastercam for SolidWorks Wins Gold Partner Status

Peter Gossas president of Sandvik Materials Tech-nology for nine years will retire and leave the Sand-vik Group on May 31 2011 Jonas Gustavsson (pictured) currently president of the Wire and Heating Technol-ogy product area within Sandvik Materials Technol-ogy has been appointed as the business divisionrsquos new president He also becomes

a member of Sandvikrsquos group executive managementSandvik Materials Technology is the Sandvik business

area that supplies metalworking materials It occupies a position within the group equivalent to that of Sandvik Coromant the cutting-tools division

Gustavsson who earned a degree in mechanical engi-neering from Lulearing Technical University has acquired solid industry experience by holding senior positions within and outside Sandvik Says Olof Faxander president and CEO of Sandvik AB ldquoWith his broad background and proven ability

The Mastercam for SolidWorksreg software package developed by CNC Software Inc to support Solid-Worksreg 3D CAD software has been awarded Certified Gold Partner status by Dassault Systegravemes SolidWorks Corp Designers engineers and machinists use Mas-tercam for SolidWorks software to programme tool paths after designs have been finished in SolidWorks The tool paths are applied directly to the SolidWorks model in their native environment Thus users of Mastercam for SolidWorks and SolidWorks 2011 in combination can employ Mastercamreg CAM technolo-gy to create a machining programme without leaving the SolidWorks interface

ldquoWith our tool paths running directly in the Solid-Works environment our users will feel comfortable programming their parts just as if they were in stan-dard Mastercamrdquo explains CNC Software marketing manager Ben Mund ldquoThe beauty is that now they can run those tool paths inside of SolidWorks with-out the hassle of exporting files and handling the translationrdquo

The point of the cooperation as Nick Iwaskow SolidWorksrsquo manager of alliances points out is that ldquointegration between key product design applica-tions can shave precious time off of the develop-ment process and increase productivityrdquo Ultimately designers and engineers can improve their designs

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

raquo CNC Software IncTolland CT USAwwwmastercamcom

STRACK NORMAGmbH amp Co KGKoumlnigsberger Str 11D-58511 Luumldenscheid

Tailor - MadeSolutions

NEW

CENTRING ELEMENTSfree of play bull wear-free bull with needle rollers

Tel +49 (0) 2351 8701-0Fax +49 (0) 2351 8701-100wwwstrackdeinfostrackde

to successfully drive change Jonas Gustavsson has the right profile to lead Sandvik Materials Technologyrdquo

Faxander also acknowledges the achievements of Gos-sas noting that the outgoing president could take credit for moving the product programme increasingly toward high-value-added products improving manufacturing pro-cesses and stepping up product development

11

Industry News

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

phone +49 (0) 92529993-0

fax +49 (0) 92529993-33

vertriebrainer-knarrde

wwwrainer-knarrde

Visit us

hall 4 booth D62

- shaft without bulge

- head underneath and

head diameter ground

- height of head 0-003

- suitable as contour pin

- high temperature resistance

- ability for coating and nitration

- wide range of dimensions

Contact UK and Ireland

Gunther UK Limited

phone 01474879774

infogunthercouk

Contact Czech Republic

wwwrsmplastcz

ISO 90012008

certified

Innovative waved

baffle profile

- shorter cycle times

- improved cooling-effect

- swirl of the medium

- prolongable up to 625mm

- temperature resistant 200degC max

Protected

system

Reduce cycle times with the new generation of

cooling deflection baffles

Ejectors - outline pins

hardened approx 53 HRC

With 78 manufacturers suppliers and service providers from the addi-tive technologies sector having con-firmed their participation as exhibi-tors at EuroMold 2011 the trade fair for mould making and tooling design and application development is extending its claim to be the most important European marketplace for this growing industrial field also known as e-production Numerous market-leading innovators specializ-ing in additive manufacturing will be presenting themselves at the Frank-furt Exhibition Centre November 29 through December 2 particularly in Hall 11

The EuroMold organizer DEMAT GmbH has provided additional show-cases for the additive technologies sector through its offer of the uni-

versity researchndashbased special-focus show within a show ldquoe-Production for Everyonerdquo this year in its third edi-tion and the globally renowned Inter-national Wohlers Conference In 2011 the 13th Wohlers Conference will feature an emphasis on design in the production of additives

E-production experts think 2011 will be a year of strong growth driven by the release of pent-up demand for new product development technol-

ogies and services ldquoAs companies investigate additive manufacturing for the production of end-use prod-ucts a new level of technology adop-tion will unfoldrdquo says Terry Wohlers CEO of Wohlers Associates Inc

EuroMold 2011 presents the entire spectrum of additive technologies and their uses including 3D-printed products for industrial applications Among the top global companies dis-playing their latest materials tech-nologies and applications will be 3D Systems Alphacam Concept Laser EOS FIT Huntsman Materialise MTT Objet Realizer SLM Solutions Strata-sys and Z Corp

EuroMold 2011 Is Planned to Solidify Position As Premiere Additive Technologies Marketplace

raquo EuroMold 2011FrankfurtMain Germanywwweuromoldcom

EURO

MO

LD

12

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

In Sosnowiec Poland prepara-tions are in full swing for Toolex 2011 the International Machine Tools Tools and Processing Tech-nology Fair which is scheduled to take place October 5ndash7 at the Expo Silesia Exhibition Cen-tre This prestigious event for the metal-processing industry attracts more and more indus-try experts every year In 2010 more than 6000 professional and expert show visitors were very satisfied by what they found at the 167 exhibition stands showcasing over 350 companies from more than two dozen coun-tries around the world

Toolex always offers a compre-hensive presentation of machine tools specialized tools tech-nological equipment software and measuring and control instruments including world premieres of many machines and tools Last year in an exhibition area extending over more than 4000 m2 181 metal-processing machine tools on display were in full operation The venue is equipped to allow exhibitors to display large and

complex operating machines includ-ing entire assembly lines

The exhibition facility in Sosno wiec is situated in the heart of Polandrsquos most industrial region which is also an important scientific centre The area of Silesia and Zaglebie is home to a range of fast-growing industri-al sectors such as the automotive

aviation and mechanical engineer-ing industries among others Also the Czech Republic and Slovakia are nearby Transportation access to the venue is well developed

Expo Silesia Expects Toolex 2011 to Be Another Successful Metal-Processing Fair

raquo Toolex 2011Sosnowiec Polandwwwtoolexpl

MCH Swiss Exhibition (Basel) Ltd has handed over the organization and operation of Swisstech Europersquos Central Fair for the Subcontracting Industries to its wholly owned sub-sidiary Exhibit amp More AG The latter company now is in charge of Swiss-tech 2012 scheduled for November 20ndash23 2012 in Basel Exhibit amp More headquartered near Zuumlrich has been organizing specialist industrial fairs for more than 30 years

Swisstech is a key meeting point

The MCH Group assumed full con-trol of Exhibit amp More at the beginning of 2010 The managers of both trade fair organizing entities are convinced that the merger of their forces will make it possible to position Swisstech and Prodex in the market more effi-ciently and to steer a course toward a successful future

Swisstech Fair Henceforward in Hands of MCH Messe Basel Subsidiary Exhibit amp More

raquo Exhibit amp More AGFaumlllanden-Zuumlrich Switzerlandwwwexhibitandmorech

every two years for the subcontract-ing industry companies operating in the fields of procurement manu-facturing and production technolo-gy MCHmdashalso known as MCH Messe Baselmdashhas used Swisstech to high-light the synergies that exist between the mechanical engineering industry and the world of specialist suppliers It has also organized Prodex the spe-cialist exhibition for machine tools tools and production measurement in parallel with Swisstech since 2004

Who knocks PET bottles into shape

CorroPlastreg

ndash the ultimate steel forall-stainless mould sets

DEUTSCHE EDELSTAHLWERKE Obere Kaiserstr D-57078 Siegen Auestr 4 D-58452 Witten

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Industry News

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

Interactive Meusburger Catalogue Provides Free Standard Parts Calculation

Version 50 of the interactive CD catalogue issued by Meusburger the Austrian manufacturer of standard parts has many new features The catalogue software includes new products for mould making as well as the entire punching tool product range a recent addition to the Meusburger portfolio The company has prided itself on setting industry trends for digital catalogues and the advanced features in the latest CD version continue the customer-oriented tradition

The software is equipped with a mould assistant for injection moulding tools and a die-set assistant for punch-ing-tool construction Selecting various plates from a mod-ular system users can assemble mould tools and die sets with just a few clicks of the mouse The software then cal-culates all necessary accessories fully automatically and free of charge The CD catalogue includes 3D models of more than 46000 Meusburger products which are easily exported into all current CAD systems and as neutral data

By displaying individual prices for different customers the digital catalogue renders inquiries obsolete Also the integrated e-mail function makes ordering a faster and simpler process Useful search options and new group fil-ters (with pictures) help save time and effort in looking for products And finally an automatic update feature makes sure that users are working with the latest software and will not miss any newly introduced products

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo FIP Solution Plastique 2011Lyon Francewwwf-i-pcom

raquo Eberhard WerkzeugtechnologieNordheim Germanywwweberhardde

FIP 2011 Plastics Industry Exhibition Due in Lyon in May

Eberhard GmbH Enjoys a 28 Increase in Turnover in 2010

From May 24 to 27 the Rhocircne capital of Lyon will host FIP Solution Plastique 2011 the Plastics Industry Exhibition in France FIP is the only French trade show that brings all of the plastics industry players togeth-er in one place in this case the Lyon Eurexpo More than 500 exhibitors representing all aspects of the plas-tics industry will be on hand These include upstream suppliers of raw materials as well as producers or pro-viders of machines and equipment moulds and tools design services prototypes and models inspection technologies for quality control soft-ware and recycling technology Pro-cessors directly connected with final clients will be present in the area des-ignated FIPrsquoProjets

Because innovation is so important for companies wishing to stand out in

Gebruumlder Eberhard GmbH the par-ent company of the tool technology specialist Eberhard Werkzeugtech-nologie increased its turnover to just under euro90 million in 2010 a 28 rise Thus the company has managed to top the highest figure it had achieved before the period of economic crisis Meanwhile its staff increased by 10 last year to 440 employees

Eberhard GmbH manufactures stan-dard parts and accessories for tools in Nordheim and runs a specialized electrical retail outlet in Heilbronn as well as operating an additional tool technology production site in Thuringia and another electrical retail outlet in Saxony

Z 107101 Z 107105

The new universalneedle valvepermits the construction of compactmoulds and simplifies the integration of the needle valve systems in manyapplications

Unique flexibility in nozzle length and diameter

Can be used with all standard nozzles

Flexible valve pin strokeup to 7 mm

Available for 2 needle diameters (2 and 25 mm)

Flexible drive solutions Hydraulic internal or pneumatic external

No melt split in the diverting unit

Integration in stack and tandem moulds is possible

Minimum mounting space

HASCO Hasenclever GmbH+Co KGIm Wiesental 77 middot D-58513 LuumldenscheidTel +49 2351 957-0 middot Fax +49 2351 957-237E-mail infohascocom middot wwwhascocom

Together we shape your ideas

Improved colour change properties

the market FIP Solu-tion Plastique 2011 includes the Innova-tion Forum which offers a harmonized overview of recent industry develop-

ments Exhibitors in 15- to 20-minute speeches will unveil innovative solu-tions that resulted from advanced research and new technologies The trade fair also comprises a free con-ference programme and other edu-cational offerings to complement the Innovation Forum and FIPrsquoProjets

The 4th annual Caoutchouc Caucho Gomma international meeting of the rubber and polymer industries takes place at the same time as FIP Solution Plastique 2011 and also in the Lyon Eurexpo

The company benefited from the fact that it did not reduce its work-force in 2009 despite a significant decline in turnover In fact it made extensive investments and doubled the production area in Nordheim ldquoAfter all positive continuity is what sets down-to-earth family-owned companies apartrdquo says CEO Roland Eberhard Eberhard GmbH also expanded its vocational trainee pro-gramme and has signed contracts with a second generation of students at the Cooperative University

Industry News

16

Cover Story | Interview

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

A company with a strong pres-ence in Europe Meusburger

is a long-established specialist in the field of standard moulds In the past few years the Austrian enterprise has invested consider-able resources in expanding plant capacity in an effort to keep pace with its business growth Mean-while it introduced a completely new line of tool components to

enlarge an already bulging product catalogue

A strong position in the Euro-pean market is not alone enough for Meusburger Standard Moulds however The company founded a sales office in China in 2010 ETMM spoke with the companyrsquos managing director Guntram Meusburger son of the epony-mous founder about these and other aspects of Meusburgerrsquos present and future operations

ETMM Please give us a brief history of Meusburger GmbH How did the company start and how did it reach its present statureMeusburger ldquoConcentrating on our own strengthsrdquomdashthis slogan has been guiding Meusburger ever since 1964 The company started off as a one-man business and today employs 420 members of staff By continuously focusing on its own strengths clearly struc-tured processes the targeting of products to meet customer needs

and quality assurance Meusburg-er has become a European leader in the field of standard moulds which represents the companyrsquos main product line

Which industry sector is most impor-tant to your company and which sectors are you looking to develop furtherMeusburger stands for continu-ity and growthmdashand especially for high-quality products for the tool and mould making industry Last year we created space for some new things and we became very active in many other areas as well For example we prepared the introduction of a new field of businessmdashnamely punching tool

construction for which we have developed products We want to continue on this successful path in the coming year

We are particularly proud of our modular systemndashbased punch-ing-tool standard parts which are completely new However though these products are in fact new we have managed to adapt numerous well-known Meusburger advan-tages from our injection-mould-making range for use in construct-ing the punching tools

What recent or forthcoming new tech-nologies will bring your customers more value in the futureStress-relieved standard parts that is the obvious answer Playing a key role at the beginning of the process chain these components form a reliable foundation for high-quality moulds and tools The latest investment project of Meusburger has been additional furnaces with 120 tons of loading capacity per day With this invest-ment we increased the existing capacity by more than half

Stress-relieved standard parts in particular the parts for injec-tion moulds and punching dies offer many benefits to toolmak-ers We apply the stress-relieving

Concentrating on Strengths a Mould Industry Supplier GrowsMeusburger Standard Moulds has been successful for nearly half a century and its director suggests intends not to let up

ldquoMeusburger stands for continuity and growthmdashand especially for high-quality products for the tool and mould making industry We place great value on products that provide a clear added value for our customersrdquo

Managing Director Guntram Meusburger

wwwthebrightworldofmetalscom wwwgmtnde

One date ndash one place ndash four eventsMake the most of four high-calibre trade fairs ndash for foundry technology metallurgy thermo process technology and precision castings ndash in one place and with one entrance ticket

The industriesrsquo Number 1 worldwide multiple synergies connections and networks all in just one show visit Welcome to Duumlsseldorf

The Bright Worldof MetalsDuumlsseldorf Germany 28 June ndash 02 July 2011

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Interview

heat treatment to all grades of steel That is the best prerequisite for warp-free machining of parts

What do you consider to be Meusburgerrsquos most important product rangeManufacturing plates for injection moulding and punching tools clearly is our biggest strength in rela-tion to our competitors Meusburger uses the best raw materials and suppliers and we implement a programme of complete quality assurance through-out the production process

How important is research and development to Meus-burger Standard MouldsWe place great value on products that provide a clear added value for our customers Therefore we develop new products by working together with customers to fulfill not only their specific needs but also and especially the needs of the market generally

Is Meusburger GmbH active in AsiaIn 2010 we opened a new sales office in Wuxi China in Jiangsu Province The reason for that is that many of our customers have manufacturing operations in China and have expressed an inter-est in using standard products made by Meusburger there As a supplier of high-quality standard parts we naturally thought it was important for us to have an in-country sales office of our own

Incidentally from May 17 to May 20 this year Meusburger GmbH will be represented for the first time at the Chinaplas trade fair which is being held in the city of Guangzhou China We invite read-ers intending to visit that show to come see us at Stand D 41 in Hall 32

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

The investment of millions of euros in the Meusburger production facility in Wolfurt in recent years extended the companyrsquos capabilities For example new furnaces allow the standard parts manufacturer to produce stress-relieved components in greater volume

18

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Advanced series of customized hot runner systems a thoroughly innovative new solution

from DME has been designed to free mould makers from the limita-tions imposed by ldquohalf-

standardrdquo solutionsmdashthat is the use of standard

products to construct a special hot runner system

With the concept-products of the Advanced series the

moulder receives a fully cus-tomer-specific system tailored

to defined needs without any compromising that will perform

exactly as it should

This hot runner series was made possible by the development of sev-eral different nozzle tips with new openings These provide an opti-mal solution for every material and accommodate lateral-injection and multiple-gating requirements Within 24 hours of request DME will offer a quotation for a complex hot runner solution including a 3D drawing and a multiflow system if needed Deliv-ery of such a system can be expect-ed in 7 to 20 working days depend-ing on the complexity plus transport Expedited delivery also is available

raquo DME EuropeMechelen Belgiumwwwdmeeucom

Custom Hot Runners without Compromise Are Available via New System Solution

Rainer Knarr Vertriebs GmbH spe-cializes in the manufacture and sup-ply of standard and custom mould parts The company prides itself on including in its standards line mould accessories that other suppliers might offer only as specials

Beyond its extensive range of stan-dard components Rainer Knarr also provides custom mould components for tool and mould makers and injec-tion-moulders such as flat ejector pins with corner radius flat ejector pins with an extralong blade step-less sleeve ejectors pins that have a diamondlike-carbon (DLC) coating (photo) ejectors with an antitwist lock and many others All of these so-called standardized specials come in a wide range of stocked dimensions

The Rainer Knarr Group operates its own mould making division There-fore it well understands the needs and challenges of mould makers and

injection moulders The supplier sup-ports customers by offering a flexible ordering and deliv-ery servicemdashwith same-day shipping even for emergency orders received on Saturdaymdashan on-line shop and CAD data that is available for downloading

Always working on developing better solutions Rainer Knarr has recently launched several new product lines One is the huge XXL programme of flat ejector pins This line features pins in dimensions other than the well-known standard ones In addition it includes flat ejec-tors with corner radii and a DLC coat-ing flat ejectors with a long sheet and high-speed flat ejectors

Another line con-sists of patented hardened or nitrid-ed stepless ejector sleeves designed to facilitate reduction of the guide length

Also new from Rainer Knarr is a range of waved deflection baffles made of plastic which help ensure efficient balanced

mould cooling And the last highlight-ed recent introduction from the com-pany is a series of ejectors for outline pins that are made of hot-working steel hardened to 53 HRc for opti-mum machinability

Service-Oriented Supplier Provides Standard Mould Parts and Standardized Specials

raquo Rainer Knarr Vertriebs GmbHHelmbrechts Germanywwwrainer-knarrde

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

8

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

With more than 15000 installed seats of its CAM software world-wide and a global network of more than 120 resellers in 50 countries SolidCAM GmbH has enjoyed great success The companyrsquos biggest mar-ket is Germany where some 2000 users are working

The CAM Competence Centre of

Husky Injection Molding Systems is expected to complete its acquisition of KTW a global manufacturer of clo-sure moulds that is headquartered in Waidhofen Austria in May 2011 The purchase represents a logical next step in a 14-year relationship between the companies

Husky and KTW have worked together to develop closure manu-facturing systems that enhance cus-tomersrsquo productivity while eliminat-ing waste and improving part quality explains John Galt Husky president and CEO But even closer collaboration was seen to be necessary for meeting

DPS Software GmbH has contributed nicely to this success in Germany as was acknowledged during a recent ceremony at SolidCAM headquarters in Schramberg There Stephan Ter-horst the software developerrsquos Ger-man marketing director presented the award for most successful world-wide SolidCAM reseller in 2010 to Joumlrg

Rudig (at right in photo) the manager of the DPS CAM Competence Centre and his staff of 13

DPS Software has 13 subsidiaries and 145 employees making it one of the biggest product lifecycle manage-ment project partners in Germany Austria and Switzerland An important growth engine for the companyrsquos prow-ess in integrated CAD CAE CAM PDM and ERP software solutions and related services is its CAM Compe-tence Centre Since the time the cen-tre was founded in 2000 the com-petence centre team has provided an integrated SolidWorksSolidCAM CADCAM solution for more than 1500 CNC machines As Joumlrg Rudig points out a key part of DPSrsquos service offering is the provision of customer-oriented training programmes to sup-port its CADCAM products

increasingly high expectations partic-ularly in developing the core elements of closure systems

Husky will offer KTW-branded clo-sure moulds as part of its line of fully integrated turnkey systems when the deal is concluded making it the clo-sure industryrsquos only provider of com-plete injection moulding systems including the mould machine hot runner and temperature controller as well as consulting and after-sales ser-vices KTW managing directors Anja and Claus Ziegler will continue to be involved at the top management level

KTW operations in Austria the Czech Republic and Germany are to become Huskyrsquos closure mould devel-opment and manufacturing cen-tres of excellence In addition Husky plans to initiate a strategic review of KTWrsquos custom injection mould-ing division Injectoplast in order to ensure the divisionrsquos future success and avoid potential conflicts of inter-est with its own customers

SolidCAM Presents DPS Software with Global Best Reseller Award for 2010

raquo SolidCAM GmbHSchramberg Germanywwwsolidcamde

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Husky Solidifies Its Position in Closure-Mould Market through Acquisition of KTW

Molded to your needs

www3dscommoldandtooling

Mold amp ToolingBoost your efficiency and save time with a robust and innovative approach

CATIA Mold amp Tooling brings the extra added value of an integrated end-to-end solution From design and engineering to simulation and manufacturing take advantage of proven

optimized processes to satisfy the increasing expectations of your customers

ww

w3

dsc

om

copy

Das

saul

t Sy

stegravem

es 2

011

ndash A

ll ri

ghts

rese

rved

ndash C

ATI

A is

a re

gist

ered

tra

dem

ark

of D

assa

ult

Syst

egravemes

or

its

subs

idia

ries

in t

he U

S an

d

or o

ther

cou

ntri

es

10

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Industry News

New President for Sandvik Materials Technology

Mastercam for SolidWorks Wins Gold Partner Status

Peter Gossas president of Sandvik Materials Tech-nology for nine years will retire and leave the Sand-vik Group on May 31 2011 Jonas Gustavsson (pictured) currently president of the Wire and Heating Technol-ogy product area within Sandvik Materials Technol-ogy has been appointed as the business divisionrsquos new president He also becomes

a member of Sandvikrsquos group executive managementSandvik Materials Technology is the Sandvik business

area that supplies metalworking materials It occupies a position within the group equivalent to that of Sandvik Coromant the cutting-tools division

Gustavsson who earned a degree in mechanical engi-neering from Lulearing Technical University has acquired solid industry experience by holding senior positions within and outside Sandvik Says Olof Faxander president and CEO of Sandvik AB ldquoWith his broad background and proven ability

The Mastercam for SolidWorksreg software package developed by CNC Software Inc to support Solid-Worksreg 3D CAD software has been awarded Certified Gold Partner status by Dassault Systegravemes SolidWorks Corp Designers engineers and machinists use Mas-tercam for SolidWorks software to programme tool paths after designs have been finished in SolidWorks The tool paths are applied directly to the SolidWorks model in their native environment Thus users of Mastercam for SolidWorks and SolidWorks 2011 in combination can employ Mastercamreg CAM technolo-gy to create a machining programme without leaving the SolidWorks interface

ldquoWith our tool paths running directly in the Solid-Works environment our users will feel comfortable programming their parts just as if they were in stan-dard Mastercamrdquo explains CNC Software marketing manager Ben Mund ldquoThe beauty is that now they can run those tool paths inside of SolidWorks with-out the hassle of exporting files and handling the translationrdquo

The point of the cooperation as Nick Iwaskow SolidWorksrsquo manager of alliances points out is that ldquointegration between key product design applica-tions can shave precious time off of the develop-ment process and increase productivityrdquo Ultimately designers and engineers can improve their designs

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

raquo CNC Software IncTolland CT USAwwwmastercamcom

STRACK NORMAGmbH amp Co KGKoumlnigsberger Str 11D-58511 Luumldenscheid

Tailor - MadeSolutions

NEW

CENTRING ELEMENTSfree of play bull wear-free bull with needle rollers

Tel +49 (0) 2351 8701-0Fax +49 (0) 2351 8701-100wwwstrackdeinfostrackde

to successfully drive change Jonas Gustavsson has the right profile to lead Sandvik Materials Technologyrdquo

Faxander also acknowledges the achievements of Gos-sas noting that the outgoing president could take credit for moving the product programme increasingly toward high-value-added products improving manufacturing pro-cesses and stepping up product development

11

Industry News

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

phone +49 (0) 92529993-0

fax +49 (0) 92529993-33

vertriebrainer-knarrde

wwwrainer-knarrde

Visit us

hall 4 booth D62

- shaft without bulge

- head underneath and

head diameter ground

- height of head 0-003

- suitable as contour pin

- high temperature resistance

- ability for coating and nitration

- wide range of dimensions

Contact UK and Ireland

Gunther UK Limited

phone 01474879774

infogunthercouk

Contact Czech Republic

wwwrsmplastcz

ISO 90012008

certified

Innovative waved

baffle profile

- shorter cycle times

- improved cooling-effect

- swirl of the medium

- prolongable up to 625mm

- temperature resistant 200degC max

Protected

system

Reduce cycle times with the new generation of

cooling deflection baffles

Ejectors - outline pins

hardened approx 53 HRC

With 78 manufacturers suppliers and service providers from the addi-tive technologies sector having con-firmed their participation as exhibi-tors at EuroMold 2011 the trade fair for mould making and tooling design and application development is extending its claim to be the most important European marketplace for this growing industrial field also known as e-production Numerous market-leading innovators specializ-ing in additive manufacturing will be presenting themselves at the Frank-furt Exhibition Centre November 29 through December 2 particularly in Hall 11

The EuroMold organizer DEMAT GmbH has provided additional show-cases for the additive technologies sector through its offer of the uni-

versity researchndashbased special-focus show within a show ldquoe-Production for Everyonerdquo this year in its third edi-tion and the globally renowned Inter-national Wohlers Conference In 2011 the 13th Wohlers Conference will feature an emphasis on design in the production of additives

E-production experts think 2011 will be a year of strong growth driven by the release of pent-up demand for new product development technol-

ogies and services ldquoAs companies investigate additive manufacturing for the production of end-use prod-ucts a new level of technology adop-tion will unfoldrdquo says Terry Wohlers CEO of Wohlers Associates Inc

EuroMold 2011 presents the entire spectrum of additive technologies and their uses including 3D-printed products for industrial applications Among the top global companies dis-playing their latest materials tech-nologies and applications will be 3D Systems Alphacam Concept Laser EOS FIT Huntsman Materialise MTT Objet Realizer SLM Solutions Strata-sys and Z Corp

EuroMold 2011 Is Planned to Solidify Position As Premiere Additive Technologies Marketplace

raquo EuroMold 2011FrankfurtMain Germanywwweuromoldcom

EURO

MO

LD

12

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

In Sosnowiec Poland prepara-tions are in full swing for Toolex 2011 the International Machine Tools Tools and Processing Tech-nology Fair which is scheduled to take place October 5ndash7 at the Expo Silesia Exhibition Cen-tre This prestigious event for the metal-processing industry attracts more and more indus-try experts every year In 2010 more than 6000 professional and expert show visitors were very satisfied by what they found at the 167 exhibition stands showcasing over 350 companies from more than two dozen coun-tries around the world

Toolex always offers a compre-hensive presentation of machine tools specialized tools tech-nological equipment software and measuring and control instruments including world premieres of many machines and tools Last year in an exhibition area extending over more than 4000 m2 181 metal-processing machine tools on display were in full operation The venue is equipped to allow exhibitors to display large and

complex operating machines includ-ing entire assembly lines

The exhibition facility in Sosno wiec is situated in the heart of Polandrsquos most industrial region which is also an important scientific centre The area of Silesia and Zaglebie is home to a range of fast-growing industri-al sectors such as the automotive

aviation and mechanical engineer-ing industries among others Also the Czech Republic and Slovakia are nearby Transportation access to the venue is well developed

Expo Silesia Expects Toolex 2011 to Be Another Successful Metal-Processing Fair

raquo Toolex 2011Sosnowiec Polandwwwtoolexpl

MCH Swiss Exhibition (Basel) Ltd has handed over the organization and operation of Swisstech Europersquos Central Fair for the Subcontracting Industries to its wholly owned sub-sidiary Exhibit amp More AG The latter company now is in charge of Swiss-tech 2012 scheduled for November 20ndash23 2012 in Basel Exhibit amp More headquartered near Zuumlrich has been organizing specialist industrial fairs for more than 30 years

Swisstech is a key meeting point

The MCH Group assumed full con-trol of Exhibit amp More at the beginning of 2010 The managers of both trade fair organizing entities are convinced that the merger of their forces will make it possible to position Swisstech and Prodex in the market more effi-ciently and to steer a course toward a successful future

Swisstech Fair Henceforward in Hands of MCH Messe Basel Subsidiary Exhibit amp More

raquo Exhibit amp More AGFaumlllanden-Zuumlrich Switzerlandwwwexhibitandmorech

every two years for the subcontract-ing industry companies operating in the fields of procurement manu-facturing and production technolo-gy MCHmdashalso known as MCH Messe Baselmdashhas used Swisstech to high-light the synergies that exist between the mechanical engineering industry and the world of specialist suppliers It has also organized Prodex the spe-cialist exhibition for machine tools tools and production measurement in parallel with Swisstech since 2004

Who knocks PET bottles into shape

CorroPlastreg

ndash the ultimate steel forall-stainless mould sets

DEUTSCHE EDELSTAHLWERKE Obere Kaiserstr D-57078 Siegen Auestr 4 D-58452 Witten

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Industry News

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

Interactive Meusburger Catalogue Provides Free Standard Parts Calculation

Version 50 of the interactive CD catalogue issued by Meusburger the Austrian manufacturer of standard parts has many new features The catalogue software includes new products for mould making as well as the entire punching tool product range a recent addition to the Meusburger portfolio The company has prided itself on setting industry trends for digital catalogues and the advanced features in the latest CD version continue the customer-oriented tradition

The software is equipped with a mould assistant for injection moulding tools and a die-set assistant for punch-ing-tool construction Selecting various plates from a mod-ular system users can assemble mould tools and die sets with just a few clicks of the mouse The software then cal-culates all necessary accessories fully automatically and free of charge The CD catalogue includes 3D models of more than 46000 Meusburger products which are easily exported into all current CAD systems and as neutral data

By displaying individual prices for different customers the digital catalogue renders inquiries obsolete Also the integrated e-mail function makes ordering a faster and simpler process Useful search options and new group fil-ters (with pictures) help save time and effort in looking for products And finally an automatic update feature makes sure that users are working with the latest software and will not miss any newly introduced products

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo FIP Solution Plastique 2011Lyon Francewwwf-i-pcom

raquo Eberhard WerkzeugtechnologieNordheim Germanywwweberhardde

FIP 2011 Plastics Industry Exhibition Due in Lyon in May

Eberhard GmbH Enjoys a 28 Increase in Turnover in 2010

From May 24 to 27 the Rhocircne capital of Lyon will host FIP Solution Plastique 2011 the Plastics Industry Exhibition in France FIP is the only French trade show that brings all of the plastics industry players togeth-er in one place in this case the Lyon Eurexpo More than 500 exhibitors representing all aspects of the plas-tics industry will be on hand These include upstream suppliers of raw materials as well as producers or pro-viders of machines and equipment moulds and tools design services prototypes and models inspection technologies for quality control soft-ware and recycling technology Pro-cessors directly connected with final clients will be present in the area des-ignated FIPrsquoProjets

Because innovation is so important for companies wishing to stand out in

Gebruumlder Eberhard GmbH the par-ent company of the tool technology specialist Eberhard Werkzeugtech-nologie increased its turnover to just under euro90 million in 2010 a 28 rise Thus the company has managed to top the highest figure it had achieved before the period of economic crisis Meanwhile its staff increased by 10 last year to 440 employees

Eberhard GmbH manufactures stan-dard parts and accessories for tools in Nordheim and runs a specialized electrical retail outlet in Heilbronn as well as operating an additional tool technology production site in Thuringia and another electrical retail outlet in Saxony

Z 107101 Z 107105

The new universalneedle valvepermits the construction of compactmoulds and simplifies the integration of the needle valve systems in manyapplications

Unique flexibility in nozzle length and diameter

Can be used with all standard nozzles

Flexible valve pin strokeup to 7 mm

Available for 2 needle diameters (2 and 25 mm)

Flexible drive solutions Hydraulic internal or pneumatic external

No melt split in the diverting unit

Integration in stack and tandem moulds is possible

Minimum mounting space

HASCO Hasenclever GmbH+Co KGIm Wiesental 77 middot D-58513 LuumldenscheidTel +49 2351 957-0 middot Fax +49 2351 957-237E-mail infohascocom middot wwwhascocom

Together we shape your ideas

Improved colour change properties

the market FIP Solu-tion Plastique 2011 includes the Innova-tion Forum which offers a harmonized overview of recent industry develop-

ments Exhibitors in 15- to 20-minute speeches will unveil innovative solu-tions that resulted from advanced research and new technologies The trade fair also comprises a free con-ference programme and other edu-cational offerings to complement the Innovation Forum and FIPrsquoProjets

The 4th annual Caoutchouc Caucho Gomma international meeting of the rubber and polymer industries takes place at the same time as FIP Solution Plastique 2011 and also in the Lyon Eurexpo

The company benefited from the fact that it did not reduce its work-force in 2009 despite a significant decline in turnover In fact it made extensive investments and doubled the production area in Nordheim ldquoAfter all positive continuity is what sets down-to-earth family-owned companies apartrdquo says CEO Roland Eberhard Eberhard GmbH also expanded its vocational trainee pro-gramme and has signed contracts with a second generation of students at the Cooperative University

Industry News

16

Cover Story | Interview

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

A company with a strong pres-ence in Europe Meusburger

is a long-established specialist in the field of standard moulds In the past few years the Austrian enterprise has invested consider-able resources in expanding plant capacity in an effort to keep pace with its business growth Mean-while it introduced a completely new line of tool components to

enlarge an already bulging product catalogue

A strong position in the Euro-pean market is not alone enough for Meusburger Standard Moulds however The company founded a sales office in China in 2010 ETMM spoke with the companyrsquos managing director Guntram Meusburger son of the epony-mous founder about these and other aspects of Meusburgerrsquos present and future operations

ETMM Please give us a brief history of Meusburger GmbH How did the company start and how did it reach its present statureMeusburger ldquoConcentrating on our own strengthsrdquomdashthis slogan has been guiding Meusburger ever since 1964 The company started off as a one-man business and today employs 420 members of staff By continuously focusing on its own strengths clearly struc-tured processes the targeting of products to meet customer needs

and quality assurance Meusburg-er has become a European leader in the field of standard moulds which represents the companyrsquos main product line

Which industry sector is most impor-tant to your company and which sectors are you looking to develop furtherMeusburger stands for continu-ity and growthmdashand especially for high-quality products for the tool and mould making industry Last year we created space for some new things and we became very active in many other areas as well For example we prepared the introduction of a new field of businessmdashnamely punching tool

construction for which we have developed products We want to continue on this successful path in the coming year

We are particularly proud of our modular systemndashbased punch-ing-tool standard parts which are completely new However though these products are in fact new we have managed to adapt numerous well-known Meusburger advan-tages from our injection-mould-making range for use in construct-ing the punching tools

What recent or forthcoming new tech-nologies will bring your customers more value in the futureStress-relieved standard parts that is the obvious answer Playing a key role at the beginning of the process chain these components form a reliable foundation for high-quality moulds and tools The latest investment project of Meusburger has been additional furnaces with 120 tons of loading capacity per day With this invest-ment we increased the existing capacity by more than half

Stress-relieved standard parts in particular the parts for injec-tion moulds and punching dies offer many benefits to toolmak-ers We apply the stress-relieving

Concentrating on Strengths a Mould Industry Supplier GrowsMeusburger Standard Moulds has been successful for nearly half a century and its director suggests intends not to let up

ldquoMeusburger stands for continuity and growthmdashand especially for high-quality products for the tool and mould making industry We place great value on products that provide a clear added value for our customersrdquo

Managing Director Guntram Meusburger

wwwthebrightworldofmetalscom wwwgmtnde

One date ndash one place ndash four eventsMake the most of four high-calibre trade fairs ndash for foundry technology metallurgy thermo process technology and precision castings ndash in one place and with one entrance ticket

The industriesrsquo Number 1 worldwide multiple synergies connections and networks all in just one show visit Welcome to Duumlsseldorf

The Bright Worldof MetalsDuumlsseldorf Germany 28 June ndash 02 July 2011

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Interview

heat treatment to all grades of steel That is the best prerequisite for warp-free machining of parts

What do you consider to be Meusburgerrsquos most important product rangeManufacturing plates for injection moulding and punching tools clearly is our biggest strength in rela-tion to our competitors Meusburger uses the best raw materials and suppliers and we implement a programme of complete quality assurance through-out the production process

How important is research and development to Meus-burger Standard MouldsWe place great value on products that provide a clear added value for our customers Therefore we develop new products by working together with customers to fulfill not only their specific needs but also and especially the needs of the market generally

Is Meusburger GmbH active in AsiaIn 2010 we opened a new sales office in Wuxi China in Jiangsu Province The reason for that is that many of our customers have manufacturing operations in China and have expressed an inter-est in using standard products made by Meusburger there As a supplier of high-quality standard parts we naturally thought it was important for us to have an in-country sales office of our own

Incidentally from May 17 to May 20 this year Meusburger GmbH will be represented for the first time at the Chinaplas trade fair which is being held in the city of Guangzhou China We invite read-ers intending to visit that show to come see us at Stand D 41 in Hall 32

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

The investment of millions of euros in the Meusburger production facility in Wolfurt in recent years extended the companyrsquos capabilities For example new furnaces allow the standard parts manufacturer to produce stress-relieved components in greater volume

18

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Advanced series of customized hot runner systems a thoroughly innovative new solution

from DME has been designed to free mould makers from the limita-tions imposed by ldquohalf-

standardrdquo solutionsmdashthat is the use of standard

products to construct a special hot runner system

With the concept-products of the Advanced series the

moulder receives a fully cus-tomer-specific system tailored

to defined needs without any compromising that will perform

exactly as it should

This hot runner series was made possible by the development of sev-eral different nozzle tips with new openings These provide an opti-mal solution for every material and accommodate lateral-injection and multiple-gating requirements Within 24 hours of request DME will offer a quotation for a complex hot runner solution including a 3D drawing and a multiflow system if needed Deliv-ery of such a system can be expect-ed in 7 to 20 working days depend-ing on the complexity plus transport Expedited delivery also is available

raquo DME EuropeMechelen Belgiumwwwdmeeucom

Custom Hot Runners without Compromise Are Available via New System Solution

Rainer Knarr Vertriebs GmbH spe-cializes in the manufacture and sup-ply of standard and custom mould parts The company prides itself on including in its standards line mould accessories that other suppliers might offer only as specials

Beyond its extensive range of stan-dard components Rainer Knarr also provides custom mould components for tool and mould makers and injec-tion-moulders such as flat ejector pins with corner radius flat ejector pins with an extralong blade step-less sleeve ejectors pins that have a diamondlike-carbon (DLC) coating (photo) ejectors with an antitwist lock and many others All of these so-called standardized specials come in a wide range of stocked dimensions

The Rainer Knarr Group operates its own mould making division There-fore it well understands the needs and challenges of mould makers and

injection moulders The supplier sup-ports customers by offering a flexible ordering and deliv-ery servicemdashwith same-day shipping even for emergency orders received on Saturdaymdashan on-line shop and CAD data that is available for downloading

Always working on developing better solutions Rainer Knarr has recently launched several new product lines One is the huge XXL programme of flat ejector pins This line features pins in dimensions other than the well-known standard ones In addition it includes flat ejec-tors with corner radii and a DLC coat-ing flat ejectors with a long sheet and high-speed flat ejectors

Another line con-sists of patented hardened or nitrid-ed stepless ejector sleeves designed to facilitate reduction of the guide length

Also new from Rainer Knarr is a range of waved deflection baffles made of plastic which help ensure efficient balanced

mould cooling And the last highlight-ed recent introduction from the com-pany is a series of ejectors for outline pins that are made of hot-working steel hardened to 53 HRc for opti-mum machinability

Service-Oriented Supplier Provides Standard Mould Parts and Standardized Specials

raquo Rainer Knarr Vertriebs GmbHHelmbrechts Germanywwwrainer-knarrde

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

Molded to your needs

www3dscommoldandtooling

Mold amp ToolingBoost your efficiency and save time with a robust and innovative approach

CATIA Mold amp Tooling brings the extra added value of an integrated end-to-end solution From design and engineering to simulation and manufacturing take advantage of proven

optimized processes to satisfy the increasing expectations of your customers

ww

w3

dsc

om

copy

Das

saul

t Sy

stegravem

es 2

011

ndash A

ll ri

ghts

rese

rved

ndash C

ATI

A is

a re

gist

ered

tra

dem

ark

of D

assa

ult

Syst

egravemes

or

its

subs

idia

ries

in t

he U

S an

d

or o

ther

cou

ntri

es

10

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Industry News

New President for Sandvik Materials Technology

Mastercam for SolidWorks Wins Gold Partner Status

Peter Gossas president of Sandvik Materials Tech-nology for nine years will retire and leave the Sand-vik Group on May 31 2011 Jonas Gustavsson (pictured) currently president of the Wire and Heating Technol-ogy product area within Sandvik Materials Technol-ogy has been appointed as the business divisionrsquos new president He also becomes

a member of Sandvikrsquos group executive managementSandvik Materials Technology is the Sandvik business

area that supplies metalworking materials It occupies a position within the group equivalent to that of Sandvik Coromant the cutting-tools division

Gustavsson who earned a degree in mechanical engi-neering from Lulearing Technical University has acquired solid industry experience by holding senior positions within and outside Sandvik Says Olof Faxander president and CEO of Sandvik AB ldquoWith his broad background and proven ability

The Mastercam for SolidWorksreg software package developed by CNC Software Inc to support Solid-Worksreg 3D CAD software has been awarded Certified Gold Partner status by Dassault Systegravemes SolidWorks Corp Designers engineers and machinists use Mas-tercam for SolidWorks software to programme tool paths after designs have been finished in SolidWorks The tool paths are applied directly to the SolidWorks model in their native environment Thus users of Mastercam for SolidWorks and SolidWorks 2011 in combination can employ Mastercamreg CAM technolo-gy to create a machining programme without leaving the SolidWorks interface

ldquoWith our tool paths running directly in the Solid-Works environment our users will feel comfortable programming their parts just as if they were in stan-dard Mastercamrdquo explains CNC Software marketing manager Ben Mund ldquoThe beauty is that now they can run those tool paths inside of SolidWorks with-out the hassle of exporting files and handling the translationrdquo

The point of the cooperation as Nick Iwaskow SolidWorksrsquo manager of alliances points out is that ldquointegration between key product design applica-tions can shave precious time off of the develop-ment process and increase productivityrdquo Ultimately designers and engineers can improve their designs

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

raquo CNC Software IncTolland CT USAwwwmastercamcom

STRACK NORMAGmbH amp Co KGKoumlnigsberger Str 11D-58511 Luumldenscheid

Tailor - MadeSolutions

NEW

CENTRING ELEMENTSfree of play bull wear-free bull with needle rollers

Tel +49 (0) 2351 8701-0Fax +49 (0) 2351 8701-100wwwstrackdeinfostrackde

to successfully drive change Jonas Gustavsson has the right profile to lead Sandvik Materials Technologyrdquo

Faxander also acknowledges the achievements of Gos-sas noting that the outgoing president could take credit for moving the product programme increasingly toward high-value-added products improving manufacturing pro-cesses and stepping up product development

11

Industry News

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

phone +49 (0) 92529993-0

fax +49 (0) 92529993-33

vertriebrainer-knarrde

wwwrainer-knarrde

Visit us

hall 4 booth D62

- shaft without bulge

- head underneath and

head diameter ground

- height of head 0-003

- suitable as contour pin

- high temperature resistance

- ability for coating and nitration

- wide range of dimensions

Contact UK and Ireland

Gunther UK Limited

phone 01474879774

infogunthercouk

Contact Czech Republic

wwwrsmplastcz

ISO 90012008

certified

Innovative waved

baffle profile

- shorter cycle times

- improved cooling-effect

- swirl of the medium

- prolongable up to 625mm

- temperature resistant 200degC max

Protected

system

Reduce cycle times with the new generation of

cooling deflection baffles

Ejectors - outline pins

hardened approx 53 HRC

With 78 manufacturers suppliers and service providers from the addi-tive technologies sector having con-firmed their participation as exhibi-tors at EuroMold 2011 the trade fair for mould making and tooling design and application development is extending its claim to be the most important European marketplace for this growing industrial field also known as e-production Numerous market-leading innovators specializ-ing in additive manufacturing will be presenting themselves at the Frank-furt Exhibition Centre November 29 through December 2 particularly in Hall 11

The EuroMold organizer DEMAT GmbH has provided additional show-cases for the additive technologies sector through its offer of the uni-

versity researchndashbased special-focus show within a show ldquoe-Production for Everyonerdquo this year in its third edi-tion and the globally renowned Inter-national Wohlers Conference In 2011 the 13th Wohlers Conference will feature an emphasis on design in the production of additives

E-production experts think 2011 will be a year of strong growth driven by the release of pent-up demand for new product development technol-

ogies and services ldquoAs companies investigate additive manufacturing for the production of end-use prod-ucts a new level of technology adop-tion will unfoldrdquo says Terry Wohlers CEO of Wohlers Associates Inc

EuroMold 2011 presents the entire spectrum of additive technologies and their uses including 3D-printed products for industrial applications Among the top global companies dis-playing their latest materials tech-nologies and applications will be 3D Systems Alphacam Concept Laser EOS FIT Huntsman Materialise MTT Objet Realizer SLM Solutions Strata-sys and Z Corp

EuroMold 2011 Is Planned to Solidify Position As Premiere Additive Technologies Marketplace

raquo EuroMold 2011FrankfurtMain Germanywwweuromoldcom

EURO

MO

LD

12

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

In Sosnowiec Poland prepara-tions are in full swing for Toolex 2011 the International Machine Tools Tools and Processing Tech-nology Fair which is scheduled to take place October 5ndash7 at the Expo Silesia Exhibition Cen-tre This prestigious event for the metal-processing industry attracts more and more indus-try experts every year In 2010 more than 6000 professional and expert show visitors were very satisfied by what they found at the 167 exhibition stands showcasing over 350 companies from more than two dozen coun-tries around the world

Toolex always offers a compre-hensive presentation of machine tools specialized tools tech-nological equipment software and measuring and control instruments including world premieres of many machines and tools Last year in an exhibition area extending over more than 4000 m2 181 metal-processing machine tools on display were in full operation The venue is equipped to allow exhibitors to display large and

complex operating machines includ-ing entire assembly lines

The exhibition facility in Sosno wiec is situated in the heart of Polandrsquos most industrial region which is also an important scientific centre The area of Silesia and Zaglebie is home to a range of fast-growing industri-al sectors such as the automotive

aviation and mechanical engineer-ing industries among others Also the Czech Republic and Slovakia are nearby Transportation access to the venue is well developed

Expo Silesia Expects Toolex 2011 to Be Another Successful Metal-Processing Fair

raquo Toolex 2011Sosnowiec Polandwwwtoolexpl

MCH Swiss Exhibition (Basel) Ltd has handed over the organization and operation of Swisstech Europersquos Central Fair for the Subcontracting Industries to its wholly owned sub-sidiary Exhibit amp More AG The latter company now is in charge of Swiss-tech 2012 scheduled for November 20ndash23 2012 in Basel Exhibit amp More headquartered near Zuumlrich has been organizing specialist industrial fairs for more than 30 years

Swisstech is a key meeting point

The MCH Group assumed full con-trol of Exhibit amp More at the beginning of 2010 The managers of both trade fair organizing entities are convinced that the merger of their forces will make it possible to position Swisstech and Prodex in the market more effi-ciently and to steer a course toward a successful future

Swisstech Fair Henceforward in Hands of MCH Messe Basel Subsidiary Exhibit amp More

raquo Exhibit amp More AGFaumlllanden-Zuumlrich Switzerlandwwwexhibitandmorech

every two years for the subcontract-ing industry companies operating in the fields of procurement manu-facturing and production technolo-gy MCHmdashalso known as MCH Messe Baselmdashhas used Swisstech to high-light the synergies that exist between the mechanical engineering industry and the world of specialist suppliers It has also organized Prodex the spe-cialist exhibition for machine tools tools and production measurement in parallel with Swisstech since 2004

Who knocks PET bottles into shape

CorroPlastreg

ndash the ultimate steel forall-stainless mould sets

DEUTSCHE EDELSTAHLWERKE Obere Kaiserstr D-57078 Siegen Auestr 4 D-58452 Witten

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Industry News

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

Interactive Meusburger Catalogue Provides Free Standard Parts Calculation

Version 50 of the interactive CD catalogue issued by Meusburger the Austrian manufacturer of standard parts has many new features The catalogue software includes new products for mould making as well as the entire punching tool product range a recent addition to the Meusburger portfolio The company has prided itself on setting industry trends for digital catalogues and the advanced features in the latest CD version continue the customer-oriented tradition

The software is equipped with a mould assistant for injection moulding tools and a die-set assistant for punch-ing-tool construction Selecting various plates from a mod-ular system users can assemble mould tools and die sets with just a few clicks of the mouse The software then cal-culates all necessary accessories fully automatically and free of charge The CD catalogue includes 3D models of more than 46000 Meusburger products which are easily exported into all current CAD systems and as neutral data

By displaying individual prices for different customers the digital catalogue renders inquiries obsolete Also the integrated e-mail function makes ordering a faster and simpler process Useful search options and new group fil-ters (with pictures) help save time and effort in looking for products And finally an automatic update feature makes sure that users are working with the latest software and will not miss any newly introduced products

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo FIP Solution Plastique 2011Lyon Francewwwf-i-pcom

raquo Eberhard WerkzeugtechnologieNordheim Germanywwweberhardde

FIP 2011 Plastics Industry Exhibition Due in Lyon in May

Eberhard GmbH Enjoys a 28 Increase in Turnover in 2010

From May 24 to 27 the Rhocircne capital of Lyon will host FIP Solution Plastique 2011 the Plastics Industry Exhibition in France FIP is the only French trade show that brings all of the plastics industry players togeth-er in one place in this case the Lyon Eurexpo More than 500 exhibitors representing all aspects of the plas-tics industry will be on hand These include upstream suppliers of raw materials as well as producers or pro-viders of machines and equipment moulds and tools design services prototypes and models inspection technologies for quality control soft-ware and recycling technology Pro-cessors directly connected with final clients will be present in the area des-ignated FIPrsquoProjets

Because innovation is so important for companies wishing to stand out in

Gebruumlder Eberhard GmbH the par-ent company of the tool technology specialist Eberhard Werkzeugtech-nologie increased its turnover to just under euro90 million in 2010 a 28 rise Thus the company has managed to top the highest figure it had achieved before the period of economic crisis Meanwhile its staff increased by 10 last year to 440 employees

Eberhard GmbH manufactures stan-dard parts and accessories for tools in Nordheim and runs a specialized electrical retail outlet in Heilbronn as well as operating an additional tool technology production site in Thuringia and another electrical retail outlet in Saxony

Z 107101 Z 107105

The new universalneedle valvepermits the construction of compactmoulds and simplifies the integration of the needle valve systems in manyapplications

Unique flexibility in nozzle length and diameter

Can be used with all standard nozzles

Flexible valve pin strokeup to 7 mm

Available for 2 needle diameters (2 and 25 mm)

Flexible drive solutions Hydraulic internal or pneumatic external

No melt split in the diverting unit

Integration in stack and tandem moulds is possible

Minimum mounting space

HASCO Hasenclever GmbH+Co KGIm Wiesental 77 middot D-58513 LuumldenscheidTel +49 2351 957-0 middot Fax +49 2351 957-237E-mail infohascocom middot wwwhascocom

Together we shape your ideas

Improved colour change properties

the market FIP Solu-tion Plastique 2011 includes the Innova-tion Forum which offers a harmonized overview of recent industry develop-

ments Exhibitors in 15- to 20-minute speeches will unveil innovative solu-tions that resulted from advanced research and new technologies The trade fair also comprises a free con-ference programme and other edu-cational offerings to complement the Innovation Forum and FIPrsquoProjets

The 4th annual Caoutchouc Caucho Gomma international meeting of the rubber and polymer industries takes place at the same time as FIP Solution Plastique 2011 and also in the Lyon Eurexpo

The company benefited from the fact that it did not reduce its work-force in 2009 despite a significant decline in turnover In fact it made extensive investments and doubled the production area in Nordheim ldquoAfter all positive continuity is what sets down-to-earth family-owned companies apartrdquo says CEO Roland Eberhard Eberhard GmbH also expanded its vocational trainee pro-gramme and has signed contracts with a second generation of students at the Cooperative University

Industry News

16

Cover Story | Interview

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

A company with a strong pres-ence in Europe Meusburger

is a long-established specialist in the field of standard moulds In the past few years the Austrian enterprise has invested consider-able resources in expanding plant capacity in an effort to keep pace with its business growth Mean-while it introduced a completely new line of tool components to

enlarge an already bulging product catalogue

A strong position in the Euro-pean market is not alone enough for Meusburger Standard Moulds however The company founded a sales office in China in 2010 ETMM spoke with the companyrsquos managing director Guntram Meusburger son of the epony-mous founder about these and other aspects of Meusburgerrsquos present and future operations

ETMM Please give us a brief history of Meusburger GmbH How did the company start and how did it reach its present statureMeusburger ldquoConcentrating on our own strengthsrdquomdashthis slogan has been guiding Meusburger ever since 1964 The company started off as a one-man business and today employs 420 members of staff By continuously focusing on its own strengths clearly struc-tured processes the targeting of products to meet customer needs

and quality assurance Meusburg-er has become a European leader in the field of standard moulds which represents the companyrsquos main product line

Which industry sector is most impor-tant to your company and which sectors are you looking to develop furtherMeusburger stands for continu-ity and growthmdashand especially for high-quality products for the tool and mould making industry Last year we created space for some new things and we became very active in many other areas as well For example we prepared the introduction of a new field of businessmdashnamely punching tool

construction for which we have developed products We want to continue on this successful path in the coming year

We are particularly proud of our modular systemndashbased punch-ing-tool standard parts which are completely new However though these products are in fact new we have managed to adapt numerous well-known Meusburger advan-tages from our injection-mould-making range for use in construct-ing the punching tools

What recent or forthcoming new tech-nologies will bring your customers more value in the futureStress-relieved standard parts that is the obvious answer Playing a key role at the beginning of the process chain these components form a reliable foundation for high-quality moulds and tools The latest investment project of Meusburger has been additional furnaces with 120 tons of loading capacity per day With this invest-ment we increased the existing capacity by more than half

Stress-relieved standard parts in particular the parts for injec-tion moulds and punching dies offer many benefits to toolmak-ers We apply the stress-relieving

Concentrating on Strengths a Mould Industry Supplier GrowsMeusburger Standard Moulds has been successful for nearly half a century and its director suggests intends not to let up

ldquoMeusburger stands for continuity and growthmdashand especially for high-quality products for the tool and mould making industry We place great value on products that provide a clear added value for our customersrdquo

Managing Director Guntram Meusburger

wwwthebrightworldofmetalscom wwwgmtnde

One date ndash one place ndash four eventsMake the most of four high-calibre trade fairs ndash for foundry technology metallurgy thermo process technology and precision castings ndash in one place and with one entrance ticket

The industriesrsquo Number 1 worldwide multiple synergies connections and networks all in just one show visit Welcome to Duumlsseldorf

The Bright Worldof MetalsDuumlsseldorf Germany 28 June ndash 02 July 2011

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Interview

heat treatment to all grades of steel That is the best prerequisite for warp-free machining of parts

What do you consider to be Meusburgerrsquos most important product rangeManufacturing plates for injection moulding and punching tools clearly is our biggest strength in rela-tion to our competitors Meusburger uses the best raw materials and suppliers and we implement a programme of complete quality assurance through-out the production process

How important is research and development to Meus-burger Standard MouldsWe place great value on products that provide a clear added value for our customers Therefore we develop new products by working together with customers to fulfill not only their specific needs but also and especially the needs of the market generally

Is Meusburger GmbH active in AsiaIn 2010 we opened a new sales office in Wuxi China in Jiangsu Province The reason for that is that many of our customers have manufacturing operations in China and have expressed an inter-est in using standard products made by Meusburger there As a supplier of high-quality standard parts we naturally thought it was important for us to have an in-country sales office of our own

Incidentally from May 17 to May 20 this year Meusburger GmbH will be represented for the first time at the Chinaplas trade fair which is being held in the city of Guangzhou China We invite read-ers intending to visit that show to come see us at Stand D 41 in Hall 32

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

The investment of millions of euros in the Meusburger production facility in Wolfurt in recent years extended the companyrsquos capabilities For example new furnaces allow the standard parts manufacturer to produce stress-relieved components in greater volume

18

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Advanced series of customized hot runner systems a thoroughly innovative new solution

from DME has been designed to free mould makers from the limita-tions imposed by ldquohalf-

standardrdquo solutionsmdashthat is the use of standard

products to construct a special hot runner system

With the concept-products of the Advanced series the

moulder receives a fully cus-tomer-specific system tailored

to defined needs without any compromising that will perform

exactly as it should

This hot runner series was made possible by the development of sev-eral different nozzle tips with new openings These provide an opti-mal solution for every material and accommodate lateral-injection and multiple-gating requirements Within 24 hours of request DME will offer a quotation for a complex hot runner solution including a 3D drawing and a multiflow system if needed Deliv-ery of such a system can be expect-ed in 7 to 20 working days depend-ing on the complexity plus transport Expedited delivery also is available

raquo DME EuropeMechelen Belgiumwwwdmeeucom

Custom Hot Runners without Compromise Are Available via New System Solution

Rainer Knarr Vertriebs GmbH spe-cializes in the manufacture and sup-ply of standard and custom mould parts The company prides itself on including in its standards line mould accessories that other suppliers might offer only as specials

Beyond its extensive range of stan-dard components Rainer Knarr also provides custom mould components for tool and mould makers and injec-tion-moulders such as flat ejector pins with corner radius flat ejector pins with an extralong blade step-less sleeve ejectors pins that have a diamondlike-carbon (DLC) coating (photo) ejectors with an antitwist lock and many others All of these so-called standardized specials come in a wide range of stocked dimensions

The Rainer Knarr Group operates its own mould making division There-fore it well understands the needs and challenges of mould makers and

injection moulders The supplier sup-ports customers by offering a flexible ordering and deliv-ery servicemdashwith same-day shipping even for emergency orders received on Saturdaymdashan on-line shop and CAD data that is available for downloading

Always working on developing better solutions Rainer Knarr has recently launched several new product lines One is the huge XXL programme of flat ejector pins This line features pins in dimensions other than the well-known standard ones In addition it includes flat ejec-tors with corner radii and a DLC coat-ing flat ejectors with a long sheet and high-speed flat ejectors

Another line con-sists of patented hardened or nitrid-ed stepless ejector sleeves designed to facilitate reduction of the guide length

Also new from Rainer Knarr is a range of waved deflection baffles made of plastic which help ensure efficient balanced

mould cooling And the last highlight-ed recent introduction from the com-pany is a series of ejectors for outline pins that are made of hot-working steel hardened to 53 HRc for opti-mum machinability

Service-Oriented Supplier Provides Standard Mould Parts and Standardized Specials

raquo Rainer Knarr Vertriebs GmbHHelmbrechts Germanywwwrainer-knarrde

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

10

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Industry News

New President for Sandvik Materials Technology

Mastercam for SolidWorks Wins Gold Partner Status

Peter Gossas president of Sandvik Materials Tech-nology for nine years will retire and leave the Sand-vik Group on May 31 2011 Jonas Gustavsson (pictured) currently president of the Wire and Heating Technol-ogy product area within Sandvik Materials Technol-ogy has been appointed as the business divisionrsquos new president He also becomes

a member of Sandvikrsquos group executive managementSandvik Materials Technology is the Sandvik business

area that supplies metalworking materials It occupies a position within the group equivalent to that of Sandvik Coromant the cutting-tools division

Gustavsson who earned a degree in mechanical engi-neering from Lulearing Technical University has acquired solid industry experience by holding senior positions within and outside Sandvik Says Olof Faxander president and CEO of Sandvik AB ldquoWith his broad background and proven ability

The Mastercam for SolidWorksreg software package developed by CNC Software Inc to support Solid-Worksreg 3D CAD software has been awarded Certified Gold Partner status by Dassault Systegravemes SolidWorks Corp Designers engineers and machinists use Mas-tercam for SolidWorks software to programme tool paths after designs have been finished in SolidWorks The tool paths are applied directly to the SolidWorks model in their native environment Thus users of Mastercam for SolidWorks and SolidWorks 2011 in combination can employ Mastercamreg CAM technolo-gy to create a machining programme without leaving the SolidWorks interface

ldquoWith our tool paths running directly in the Solid-Works environment our users will feel comfortable programming their parts just as if they were in stan-dard Mastercamrdquo explains CNC Software marketing manager Ben Mund ldquoThe beauty is that now they can run those tool paths inside of SolidWorks with-out the hassle of exporting files and handling the translationrdquo

The point of the cooperation as Nick Iwaskow SolidWorksrsquo manager of alliances points out is that ldquointegration between key product design applica-tions can shave precious time off of the develop-ment process and increase productivityrdquo Ultimately designers and engineers can improve their designs

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

raquo CNC Software IncTolland CT USAwwwmastercamcom

STRACK NORMAGmbH amp Co KGKoumlnigsberger Str 11D-58511 Luumldenscheid

Tailor - MadeSolutions

NEW

CENTRING ELEMENTSfree of play bull wear-free bull with needle rollers

Tel +49 (0) 2351 8701-0Fax +49 (0) 2351 8701-100wwwstrackdeinfostrackde

to successfully drive change Jonas Gustavsson has the right profile to lead Sandvik Materials Technologyrdquo

Faxander also acknowledges the achievements of Gos-sas noting that the outgoing president could take credit for moving the product programme increasingly toward high-value-added products improving manufacturing pro-cesses and stepping up product development

11

Industry News

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

phone +49 (0) 92529993-0

fax +49 (0) 92529993-33

vertriebrainer-knarrde

wwwrainer-knarrde

Visit us

hall 4 booth D62

- shaft without bulge

- head underneath and

head diameter ground

- height of head 0-003

- suitable as contour pin

- high temperature resistance

- ability for coating and nitration

- wide range of dimensions

Contact UK and Ireland

Gunther UK Limited

phone 01474879774

infogunthercouk

Contact Czech Republic

wwwrsmplastcz

ISO 90012008

certified

Innovative waved

baffle profile

- shorter cycle times

- improved cooling-effect

- swirl of the medium

- prolongable up to 625mm

- temperature resistant 200degC max

Protected

system

Reduce cycle times with the new generation of

cooling deflection baffles

Ejectors - outline pins

hardened approx 53 HRC

With 78 manufacturers suppliers and service providers from the addi-tive technologies sector having con-firmed their participation as exhibi-tors at EuroMold 2011 the trade fair for mould making and tooling design and application development is extending its claim to be the most important European marketplace for this growing industrial field also known as e-production Numerous market-leading innovators specializ-ing in additive manufacturing will be presenting themselves at the Frank-furt Exhibition Centre November 29 through December 2 particularly in Hall 11

The EuroMold organizer DEMAT GmbH has provided additional show-cases for the additive technologies sector through its offer of the uni-

versity researchndashbased special-focus show within a show ldquoe-Production for Everyonerdquo this year in its third edi-tion and the globally renowned Inter-national Wohlers Conference In 2011 the 13th Wohlers Conference will feature an emphasis on design in the production of additives

E-production experts think 2011 will be a year of strong growth driven by the release of pent-up demand for new product development technol-

ogies and services ldquoAs companies investigate additive manufacturing for the production of end-use prod-ucts a new level of technology adop-tion will unfoldrdquo says Terry Wohlers CEO of Wohlers Associates Inc

EuroMold 2011 presents the entire spectrum of additive technologies and their uses including 3D-printed products for industrial applications Among the top global companies dis-playing their latest materials tech-nologies and applications will be 3D Systems Alphacam Concept Laser EOS FIT Huntsman Materialise MTT Objet Realizer SLM Solutions Strata-sys and Z Corp

EuroMold 2011 Is Planned to Solidify Position As Premiere Additive Technologies Marketplace

raquo EuroMold 2011FrankfurtMain Germanywwweuromoldcom

EURO

MO

LD

12

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

In Sosnowiec Poland prepara-tions are in full swing for Toolex 2011 the International Machine Tools Tools and Processing Tech-nology Fair which is scheduled to take place October 5ndash7 at the Expo Silesia Exhibition Cen-tre This prestigious event for the metal-processing industry attracts more and more indus-try experts every year In 2010 more than 6000 professional and expert show visitors were very satisfied by what they found at the 167 exhibition stands showcasing over 350 companies from more than two dozen coun-tries around the world

Toolex always offers a compre-hensive presentation of machine tools specialized tools tech-nological equipment software and measuring and control instruments including world premieres of many machines and tools Last year in an exhibition area extending over more than 4000 m2 181 metal-processing machine tools on display were in full operation The venue is equipped to allow exhibitors to display large and

complex operating machines includ-ing entire assembly lines

The exhibition facility in Sosno wiec is situated in the heart of Polandrsquos most industrial region which is also an important scientific centre The area of Silesia and Zaglebie is home to a range of fast-growing industri-al sectors such as the automotive

aviation and mechanical engineer-ing industries among others Also the Czech Republic and Slovakia are nearby Transportation access to the venue is well developed

Expo Silesia Expects Toolex 2011 to Be Another Successful Metal-Processing Fair

raquo Toolex 2011Sosnowiec Polandwwwtoolexpl

MCH Swiss Exhibition (Basel) Ltd has handed over the organization and operation of Swisstech Europersquos Central Fair for the Subcontracting Industries to its wholly owned sub-sidiary Exhibit amp More AG The latter company now is in charge of Swiss-tech 2012 scheduled for November 20ndash23 2012 in Basel Exhibit amp More headquartered near Zuumlrich has been organizing specialist industrial fairs for more than 30 years

Swisstech is a key meeting point

The MCH Group assumed full con-trol of Exhibit amp More at the beginning of 2010 The managers of both trade fair organizing entities are convinced that the merger of their forces will make it possible to position Swisstech and Prodex in the market more effi-ciently and to steer a course toward a successful future

Swisstech Fair Henceforward in Hands of MCH Messe Basel Subsidiary Exhibit amp More

raquo Exhibit amp More AGFaumlllanden-Zuumlrich Switzerlandwwwexhibitandmorech

every two years for the subcontract-ing industry companies operating in the fields of procurement manu-facturing and production technolo-gy MCHmdashalso known as MCH Messe Baselmdashhas used Swisstech to high-light the synergies that exist between the mechanical engineering industry and the world of specialist suppliers It has also organized Prodex the spe-cialist exhibition for machine tools tools and production measurement in parallel with Swisstech since 2004

Who knocks PET bottles into shape

CorroPlastreg

ndash the ultimate steel forall-stainless mould sets

DEUTSCHE EDELSTAHLWERKE Obere Kaiserstr D-57078 Siegen Auestr 4 D-58452 Witten

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Industry News

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

Interactive Meusburger Catalogue Provides Free Standard Parts Calculation

Version 50 of the interactive CD catalogue issued by Meusburger the Austrian manufacturer of standard parts has many new features The catalogue software includes new products for mould making as well as the entire punching tool product range a recent addition to the Meusburger portfolio The company has prided itself on setting industry trends for digital catalogues and the advanced features in the latest CD version continue the customer-oriented tradition

The software is equipped with a mould assistant for injection moulding tools and a die-set assistant for punch-ing-tool construction Selecting various plates from a mod-ular system users can assemble mould tools and die sets with just a few clicks of the mouse The software then cal-culates all necessary accessories fully automatically and free of charge The CD catalogue includes 3D models of more than 46000 Meusburger products which are easily exported into all current CAD systems and as neutral data

By displaying individual prices for different customers the digital catalogue renders inquiries obsolete Also the integrated e-mail function makes ordering a faster and simpler process Useful search options and new group fil-ters (with pictures) help save time and effort in looking for products And finally an automatic update feature makes sure that users are working with the latest software and will not miss any newly introduced products

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo FIP Solution Plastique 2011Lyon Francewwwf-i-pcom

raquo Eberhard WerkzeugtechnologieNordheim Germanywwweberhardde

FIP 2011 Plastics Industry Exhibition Due in Lyon in May

Eberhard GmbH Enjoys a 28 Increase in Turnover in 2010

From May 24 to 27 the Rhocircne capital of Lyon will host FIP Solution Plastique 2011 the Plastics Industry Exhibition in France FIP is the only French trade show that brings all of the plastics industry players togeth-er in one place in this case the Lyon Eurexpo More than 500 exhibitors representing all aspects of the plas-tics industry will be on hand These include upstream suppliers of raw materials as well as producers or pro-viders of machines and equipment moulds and tools design services prototypes and models inspection technologies for quality control soft-ware and recycling technology Pro-cessors directly connected with final clients will be present in the area des-ignated FIPrsquoProjets

Because innovation is so important for companies wishing to stand out in

Gebruumlder Eberhard GmbH the par-ent company of the tool technology specialist Eberhard Werkzeugtech-nologie increased its turnover to just under euro90 million in 2010 a 28 rise Thus the company has managed to top the highest figure it had achieved before the period of economic crisis Meanwhile its staff increased by 10 last year to 440 employees

Eberhard GmbH manufactures stan-dard parts and accessories for tools in Nordheim and runs a specialized electrical retail outlet in Heilbronn as well as operating an additional tool technology production site in Thuringia and another electrical retail outlet in Saxony

Z 107101 Z 107105

The new universalneedle valvepermits the construction of compactmoulds and simplifies the integration of the needle valve systems in manyapplications

Unique flexibility in nozzle length and diameter

Can be used with all standard nozzles

Flexible valve pin strokeup to 7 mm

Available for 2 needle diameters (2 and 25 mm)

Flexible drive solutions Hydraulic internal or pneumatic external

No melt split in the diverting unit

Integration in stack and tandem moulds is possible

Minimum mounting space

HASCO Hasenclever GmbH+Co KGIm Wiesental 77 middot D-58513 LuumldenscheidTel +49 2351 957-0 middot Fax +49 2351 957-237E-mail infohascocom middot wwwhascocom

Together we shape your ideas

Improved colour change properties

the market FIP Solu-tion Plastique 2011 includes the Innova-tion Forum which offers a harmonized overview of recent industry develop-

ments Exhibitors in 15- to 20-minute speeches will unveil innovative solu-tions that resulted from advanced research and new technologies The trade fair also comprises a free con-ference programme and other edu-cational offerings to complement the Innovation Forum and FIPrsquoProjets

The 4th annual Caoutchouc Caucho Gomma international meeting of the rubber and polymer industries takes place at the same time as FIP Solution Plastique 2011 and also in the Lyon Eurexpo

The company benefited from the fact that it did not reduce its work-force in 2009 despite a significant decline in turnover In fact it made extensive investments and doubled the production area in Nordheim ldquoAfter all positive continuity is what sets down-to-earth family-owned companies apartrdquo says CEO Roland Eberhard Eberhard GmbH also expanded its vocational trainee pro-gramme and has signed contracts with a second generation of students at the Cooperative University

Industry News

16

Cover Story | Interview

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

A company with a strong pres-ence in Europe Meusburger

is a long-established specialist in the field of standard moulds In the past few years the Austrian enterprise has invested consider-able resources in expanding plant capacity in an effort to keep pace with its business growth Mean-while it introduced a completely new line of tool components to

enlarge an already bulging product catalogue

A strong position in the Euro-pean market is not alone enough for Meusburger Standard Moulds however The company founded a sales office in China in 2010 ETMM spoke with the companyrsquos managing director Guntram Meusburger son of the epony-mous founder about these and other aspects of Meusburgerrsquos present and future operations

ETMM Please give us a brief history of Meusburger GmbH How did the company start and how did it reach its present statureMeusburger ldquoConcentrating on our own strengthsrdquomdashthis slogan has been guiding Meusburger ever since 1964 The company started off as a one-man business and today employs 420 members of staff By continuously focusing on its own strengths clearly struc-tured processes the targeting of products to meet customer needs

and quality assurance Meusburg-er has become a European leader in the field of standard moulds which represents the companyrsquos main product line

Which industry sector is most impor-tant to your company and which sectors are you looking to develop furtherMeusburger stands for continu-ity and growthmdashand especially for high-quality products for the tool and mould making industry Last year we created space for some new things and we became very active in many other areas as well For example we prepared the introduction of a new field of businessmdashnamely punching tool

construction for which we have developed products We want to continue on this successful path in the coming year

We are particularly proud of our modular systemndashbased punch-ing-tool standard parts which are completely new However though these products are in fact new we have managed to adapt numerous well-known Meusburger advan-tages from our injection-mould-making range for use in construct-ing the punching tools

What recent or forthcoming new tech-nologies will bring your customers more value in the futureStress-relieved standard parts that is the obvious answer Playing a key role at the beginning of the process chain these components form a reliable foundation for high-quality moulds and tools The latest investment project of Meusburger has been additional furnaces with 120 tons of loading capacity per day With this invest-ment we increased the existing capacity by more than half

Stress-relieved standard parts in particular the parts for injec-tion moulds and punching dies offer many benefits to toolmak-ers We apply the stress-relieving

Concentrating on Strengths a Mould Industry Supplier GrowsMeusburger Standard Moulds has been successful for nearly half a century and its director suggests intends not to let up

ldquoMeusburger stands for continuity and growthmdashand especially for high-quality products for the tool and mould making industry We place great value on products that provide a clear added value for our customersrdquo

Managing Director Guntram Meusburger

wwwthebrightworldofmetalscom wwwgmtnde

One date ndash one place ndash four eventsMake the most of four high-calibre trade fairs ndash for foundry technology metallurgy thermo process technology and precision castings ndash in one place and with one entrance ticket

The industriesrsquo Number 1 worldwide multiple synergies connections and networks all in just one show visit Welcome to Duumlsseldorf

The Bright Worldof MetalsDuumlsseldorf Germany 28 June ndash 02 July 2011

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Interview

heat treatment to all grades of steel That is the best prerequisite for warp-free machining of parts

What do you consider to be Meusburgerrsquos most important product rangeManufacturing plates for injection moulding and punching tools clearly is our biggest strength in rela-tion to our competitors Meusburger uses the best raw materials and suppliers and we implement a programme of complete quality assurance through-out the production process

How important is research and development to Meus-burger Standard MouldsWe place great value on products that provide a clear added value for our customers Therefore we develop new products by working together with customers to fulfill not only their specific needs but also and especially the needs of the market generally

Is Meusburger GmbH active in AsiaIn 2010 we opened a new sales office in Wuxi China in Jiangsu Province The reason for that is that many of our customers have manufacturing operations in China and have expressed an inter-est in using standard products made by Meusburger there As a supplier of high-quality standard parts we naturally thought it was important for us to have an in-country sales office of our own

Incidentally from May 17 to May 20 this year Meusburger GmbH will be represented for the first time at the Chinaplas trade fair which is being held in the city of Guangzhou China We invite read-ers intending to visit that show to come see us at Stand D 41 in Hall 32

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

The investment of millions of euros in the Meusburger production facility in Wolfurt in recent years extended the companyrsquos capabilities For example new furnaces allow the standard parts manufacturer to produce stress-relieved components in greater volume

18

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Advanced series of customized hot runner systems a thoroughly innovative new solution

from DME has been designed to free mould makers from the limita-tions imposed by ldquohalf-

standardrdquo solutionsmdashthat is the use of standard

products to construct a special hot runner system

With the concept-products of the Advanced series the

moulder receives a fully cus-tomer-specific system tailored

to defined needs without any compromising that will perform

exactly as it should

This hot runner series was made possible by the development of sev-eral different nozzle tips with new openings These provide an opti-mal solution for every material and accommodate lateral-injection and multiple-gating requirements Within 24 hours of request DME will offer a quotation for a complex hot runner solution including a 3D drawing and a multiflow system if needed Deliv-ery of such a system can be expect-ed in 7 to 20 working days depend-ing on the complexity plus transport Expedited delivery also is available

raquo DME EuropeMechelen Belgiumwwwdmeeucom

Custom Hot Runners without Compromise Are Available via New System Solution

Rainer Knarr Vertriebs GmbH spe-cializes in the manufacture and sup-ply of standard and custom mould parts The company prides itself on including in its standards line mould accessories that other suppliers might offer only as specials

Beyond its extensive range of stan-dard components Rainer Knarr also provides custom mould components for tool and mould makers and injec-tion-moulders such as flat ejector pins with corner radius flat ejector pins with an extralong blade step-less sleeve ejectors pins that have a diamondlike-carbon (DLC) coating (photo) ejectors with an antitwist lock and many others All of these so-called standardized specials come in a wide range of stocked dimensions

The Rainer Knarr Group operates its own mould making division There-fore it well understands the needs and challenges of mould makers and

injection moulders The supplier sup-ports customers by offering a flexible ordering and deliv-ery servicemdashwith same-day shipping even for emergency orders received on Saturdaymdashan on-line shop and CAD data that is available for downloading

Always working on developing better solutions Rainer Knarr has recently launched several new product lines One is the huge XXL programme of flat ejector pins This line features pins in dimensions other than the well-known standard ones In addition it includes flat ejec-tors with corner radii and a DLC coat-ing flat ejectors with a long sheet and high-speed flat ejectors

Another line con-sists of patented hardened or nitrid-ed stepless ejector sleeves designed to facilitate reduction of the guide length

Also new from Rainer Knarr is a range of waved deflection baffles made of plastic which help ensure efficient balanced

mould cooling And the last highlight-ed recent introduction from the com-pany is a series of ejectors for outline pins that are made of hot-working steel hardened to 53 HRc for opti-mum machinability

Service-Oriented Supplier Provides Standard Mould Parts and Standardized Specials

raquo Rainer Knarr Vertriebs GmbHHelmbrechts Germanywwwrainer-knarrde

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

11

Industry News

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

phone +49 (0) 92529993-0

fax +49 (0) 92529993-33

vertriebrainer-knarrde

wwwrainer-knarrde

Visit us

hall 4 booth D62

- shaft without bulge

- head underneath and

head diameter ground

- height of head 0-003

- suitable as contour pin

- high temperature resistance

- ability for coating and nitration

- wide range of dimensions

Contact UK and Ireland

Gunther UK Limited

phone 01474879774

infogunthercouk

Contact Czech Republic

wwwrsmplastcz

ISO 90012008

certified

Innovative waved

baffle profile

- shorter cycle times

- improved cooling-effect

- swirl of the medium

- prolongable up to 625mm

- temperature resistant 200degC max

Protected

system

Reduce cycle times with the new generation of

cooling deflection baffles

Ejectors - outline pins

hardened approx 53 HRC

With 78 manufacturers suppliers and service providers from the addi-tive technologies sector having con-firmed their participation as exhibi-tors at EuroMold 2011 the trade fair for mould making and tooling design and application development is extending its claim to be the most important European marketplace for this growing industrial field also known as e-production Numerous market-leading innovators specializ-ing in additive manufacturing will be presenting themselves at the Frank-furt Exhibition Centre November 29 through December 2 particularly in Hall 11

The EuroMold organizer DEMAT GmbH has provided additional show-cases for the additive technologies sector through its offer of the uni-

versity researchndashbased special-focus show within a show ldquoe-Production for Everyonerdquo this year in its third edi-tion and the globally renowned Inter-national Wohlers Conference In 2011 the 13th Wohlers Conference will feature an emphasis on design in the production of additives

E-production experts think 2011 will be a year of strong growth driven by the release of pent-up demand for new product development technol-

ogies and services ldquoAs companies investigate additive manufacturing for the production of end-use prod-ucts a new level of technology adop-tion will unfoldrdquo says Terry Wohlers CEO of Wohlers Associates Inc

EuroMold 2011 presents the entire spectrum of additive technologies and their uses including 3D-printed products for industrial applications Among the top global companies dis-playing their latest materials tech-nologies and applications will be 3D Systems Alphacam Concept Laser EOS FIT Huntsman Materialise MTT Objet Realizer SLM Solutions Strata-sys and Z Corp

EuroMold 2011 Is Planned to Solidify Position As Premiere Additive Technologies Marketplace

raquo EuroMold 2011FrankfurtMain Germanywwweuromoldcom

EURO

MO

LD

12

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

In Sosnowiec Poland prepara-tions are in full swing for Toolex 2011 the International Machine Tools Tools and Processing Tech-nology Fair which is scheduled to take place October 5ndash7 at the Expo Silesia Exhibition Cen-tre This prestigious event for the metal-processing industry attracts more and more indus-try experts every year In 2010 more than 6000 professional and expert show visitors were very satisfied by what they found at the 167 exhibition stands showcasing over 350 companies from more than two dozen coun-tries around the world

Toolex always offers a compre-hensive presentation of machine tools specialized tools tech-nological equipment software and measuring and control instruments including world premieres of many machines and tools Last year in an exhibition area extending over more than 4000 m2 181 metal-processing machine tools on display were in full operation The venue is equipped to allow exhibitors to display large and

complex operating machines includ-ing entire assembly lines

The exhibition facility in Sosno wiec is situated in the heart of Polandrsquos most industrial region which is also an important scientific centre The area of Silesia and Zaglebie is home to a range of fast-growing industri-al sectors such as the automotive

aviation and mechanical engineer-ing industries among others Also the Czech Republic and Slovakia are nearby Transportation access to the venue is well developed

Expo Silesia Expects Toolex 2011 to Be Another Successful Metal-Processing Fair

raquo Toolex 2011Sosnowiec Polandwwwtoolexpl

MCH Swiss Exhibition (Basel) Ltd has handed over the organization and operation of Swisstech Europersquos Central Fair for the Subcontracting Industries to its wholly owned sub-sidiary Exhibit amp More AG The latter company now is in charge of Swiss-tech 2012 scheduled for November 20ndash23 2012 in Basel Exhibit amp More headquartered near Zuumlrich has been organizing specialist industrial fairs for more than 30 years

Swisstech is a key meeting point

The MCH Group assumed full con-trol of Exhibit amp More at the beginning of 2010 The managers of both trade fair organizing entities are convinced that the merger of their forces will make it possible to position Swisstech and Prodex in the market more effi-ciently and to steer a course toward a successful future

Swisstech Fair Henceforward in Hands of MCH Messe Basel Subsidiary Exhibit amp More

raquo Exhibit amp More AGFaumlllanden-Zuumlrich Switzerlandwwwexhibitandmorech

every two years for the subcontract-ing industry companies operating in the fields of procurement manu-facturing and production technolo-gy MCHmdashalso known as MCH Messe Baselmdashhas used Swisstech to high-light the synergies that exist between the mechanical engineering industry and the world of specialist suppliers It has also organized Prodex the spe-cialist exhibition for machine tools tools and production measurement in parallel with Swisstech since 2004

Who knocks PET bottles into shape

CorroPlastreg

ndash the ultimate steel forall-stainless mould sets

DEUTSCHE EDELSTAHLWERKE Obere Kaiserstr D-57078 Siegen Auestr 4 D-58452 Witten

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Industry News

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

Interactive Meusburger Catalogue Provides Free Standard Parts Calculation

Version 50 of the interactive CD catalogue issued by Meusburger the Austrian manufacturer of standard parts has many new features The catalogue software includes new products for mould making as well as the entire punching tool product range a recent addition to the Meusburger portfolio The company has prided itself on setting industry trends for digital catalogues and the advanced features in the latest CD version continue the customer-oriented tradition

The software is equipped with a mould assistant for injection moulding tools and a die-set assistant for punch-ing-tool construction Selecting various plates from a mod-ular system users can assemble mould tools and die sets with just a few clicks of the mouse The software then cal-culates all necessary accessories fully automatically and free of charge The CD catalogue includes 3D models of more than 46000 Meusburger products which are easily exported into all current CAD systems and as neutral data

By displaying individual prices for different customers the digital catalogue renders inquiries obsolete Also the integrated e-mail function makes ordering a faster and simpler process Useful search options and new group fil-ters (with pictures) help save time and effort in looking for products And finally an automatic update feature makes sure that users are working with the latest software and will not miss any newly introduced products

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo FIP Solution Plastique 2011Lyon Francewwwf-i-pcom

raquo Eberhard WerkzeugtechnologieNordheim Germanywwweberhardde

FIP 2011 Plastics Industry Exhibition Due in Lyon in May

Eberhard GmbH Enjoys a 28 Increase in Turnover in 2010

From May 24 to 27 the Rhocircne capital of Lyon will host FIP Solution Plastique 2011 the Plastics Industry Exhibition in France FIP is the only French trade show that brings all of the plastics industry players togeth-er in one place in this case the Lyon Eurexpo More than 500 exhibitors representing all aspects of the plas-tics industry will be on hand These include upstream suppliers of raw materials as well as producers or pro-viders of machines and equipment moulds and tools design services prototypes and models inspection technologies for quality control soft-ware and recycling technology Pro-cessors directly connected with final clients will be present in the area des-ignated FIPrsquoProjets

Because innovation is so important for companies wishing to stand out in

Gebruumlder Eberhard GmbH the par-ent company of the tool technology specialist Eberhard Werkzeugtech-nologie increased its turnover to just under euro90 million in 2010 a 28 rise Thus the company has managed to top the highest figure it had achieved before the period of economic crisis Meanwhile its staff increased by 10 last year to 440 employees

Eberhard GmbH manufactures stan-dard parts and accessories for tools in Nordheim and runs a specialized electrical retail outlet in Heilbronn as well as operating an additional tool technology production site in Thuringia and another electrical retail outlet in Saxony

Z 107101 Z 107105

The new universalneedle valvepermits the construction of compactmoulds and simplifies the integration of the needle valve systems in manyapplications

Unique flexibility in nozzle length and diameter

Can be used with all standard nozzles

Flexible valve pin strokeup to 7 mm

Available for 2 needle diameters (2 and 25 mm)

Flexible drive solutions Hydraulic internal or pneumatic external

No melt split in the diverting unit

Integration in stack and tandem moulds is possible

Minimum mounting space

HASCO Hasenclever GmbH+Co KGIm Wiesental 77 middot D-58513 LuumldenscheidTel +49 2351 957-0 middot Fax +49 2351 957-237E-mail infohascocom middot wwwhascocom

Together we shape your ideas

Improved colour change properties

the market FIP Solu-tion Plastique 2011 includes the Innova-tion Forum which offers a harmonized overview of recent industry develop-

ments Exhibitors in 15- to 20-minute speeches will unveil innovative solu-tions that resulted from advanced research and new technologies The trade fair also comprises a free con-ference programme and other edu-cational offerings to complement the Innovation Forum and FIPrsquoProjets

The 4th annual Caoutchouc Caucho Gomma international meeting of the rubber and polymer industries takes place at the same time as FIP Solution Plastique 2011 and also in the Lyon Eurexpo

The company benefited from the fact that it did not reduce its work-force in 2009 despite a significant decline in turnover In fact it made extensive investments and doubled the production area in Nordheim ldquoAfter all positive continuity is what sets down-to-earth family-owned companies apartrdquo says CEO Roland Eberhard Eberhard GmbH also expanded its vocational trainee pro-gramme and has signed contracts with a second generation of students at the Cooperative University

Industry News

16

Cover Story | Interview

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

A company with a strong pres-ence in Europe Meusburger

is a long-established specialist in the field of standard moulds In the past few years the Austrian enterprise has invested consider-able resources in expanding plant capacity in an effort to keep pace with its business growth Mean-while it introduced a completely new line of tool components to

enlarge an already bulging product catalogue

A strong position in the Euro-pean market is not alone enough for Meusburger Standard Moulds however The company founded a sales office in China in 2010 ETMM spoke with the companyrsquos managing director Guntram Meusburger son of the epony-mous founder about these and other aspects of Meusburgerrsquos present and future operations

ETMM Please give us a brief history of Meusburger GmbH How did the company start and how did it reach its present statureMeusburger ldquoConcentrating on our own strengthsrdquomdashthis slogan has been guiding Meusburger ever since 1964 The company started off as a one-man business and today employs 420 members of staff By continuously focusing on its own strengths clearly struc-tured processes the targeting of products to meet customer needs

and quality assurance Meusburg-er has become a European leader in the field of standard moulds which represents the companyrsquos main product line

Which industry sector is most impor-tant to your company and which sectors are you looking to develop furtherMeusburger stands for continu-ity and growthmdashand especially for high-quality products for the tool and mould making industry Last year we created space for some new things and we became very active in many other areas as well For example we prepared the introduction of a new field of businessmdashnamely punching tool

construction for which we have developed products We want to continue on this successful path in the coming year

We are particularly proud of our modular systemndashbased punch-ing-tool standard parts which are completely new However though these products are in fact new we have managed to adapt numerous well-known Meusburger advan-tages from our injection-mould-making range for use in construct-ing the punching tools

What recent or forthcoming new tech-nologies will bring your customers more value in the futureStress-relieved standard parts that is the obvious answer Playing a key role at the beginning of the process chain these components form a reliable foundation for high-quality moulds and tools The latest investment project of Meusburger has been additional furnaces with 120 tons of loading capacity per day With this invest-ment we increased the existing capacity by more than half

Stress-relieved standard parts in particular the parts for injec-tion moulds and punching dies offer many benefits to toolmak-ers We apply the stress-relieving

Concentrating on Strengths a Mould Industry Supplier GrowsMeusburger Standard Moulds has been successful for nearly half a century and its director suggests intends not to let up

ldquoMeusburger stands for continuity and growthmdashand especially for high-quality products for the tool and mould making industry We place great value on products that provide a clear added value for our customersrdquo

Managing Director Guntram Meusburger

wwwthebrightworldofmetalscom wwwgmtnde

One date ndash one place ndash four eventsMake the most of four high-calibre trade fairs ndash for foundry technology metallurgy thermo process technology and precision castings ndash in one place and with one entrance ticket

The industriesrsquo Number 1 worldwide multiple synergies connections and networks all in just one show visit Welcome to Duumlsseldorf

The Bright Worldof MetalsDuumlsseldorf Germany 28 June ndash 02 July 2011

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Interview

heat treatment to all grades of steel That is the best prerequisite for warp-free machining of parts

What do you consider to be Meusburgerrsquos most important product rangeManufacturing plates for injection moulding and punching tools clearly is our biggest strength in rela-tion to our competitors Meusburger uses the best raw materials and suppliers and we implement a programme of complete quality assurance through-out the production process

How important is research and development to Meus-burger Standard MouldsWe place great value on products that provide a clear added value for our customers Therefore we develop new products by working together with customers to fulfill not only their specific needs but also and especially the needs of the market generally

Is Meusburger GmbH active in AsiaIn 2010 we opened a new sales office in Wuxi China in Jiangsu Province The reason for that is that many of our customers have manufacturing operations in China and have expressed an inter-est in using standard products made by Meusburger there As a supplier of high-quality standard parts we naturally thought it was important for us to have an in-country sales office of our own

Incidentally from May 17 to May 20 this year Meusburger GmbH will be represented for the first time at the Chinaplas trade fair which is being held in the city of Guangzhou China We invite read-ers intending to visit that show to come see us at Stand D 41 in Hall 32

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

The investment of millions of euros in the Meusburger production facility in Wolfurt in recent years extended the companyrsquos capabilities For example new furnaces allow the standard parts manufacturer to produce stress-relieved components in greater volume

18

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Advanced series of customized hot runner systems a thoroughly innovative new solution

from DME has been designed to free mould makers from the limita-tions imposed by ldquohalf-

standardrdquo solutionsmdashthat is the use of standard

products to construct a special hot runner system

With the concept-products of the Advanced series the

moulder receives a fully cus-tomer-specific system tailored

to defined needs without any compromising that will perform

exactly as it should

This hot runner series was made possible by the development of sev-eral different nozzle tips with new openings These provide an opti-mal solution for every material and accommodate lateral-injection and multiple-gating requirements Within 24 hours of request DME will offer a quotation for a complex hot runner solution including a 3D drawing and a multiflow system if needed Deliv-ery of such a system can be expect-ed in 7 to 20 working days depend-ing on the complexity plus transport Expedited delivery also is available

raquo DME EuropeMechelen Belgiumwwwdmeeucom

Custom Hot Runners without Compromise Are Available via New System Solution

Rainer Knarr Vertriebs GmbH spe-cializes in the manufacture and sup-ply of standard and custom mould parts The company prides itself on including in its standards line mould accessories that other suppliers might offer only as specials

Beyond its extensive range of stan-dard components Rainer Knarr also provides custom mould components for tool and mould makers and injec-tion-moulders such as flat ejector pins with corner radius flat ejector pins with an extralong blade step-less sleeve ejectors pins that have a diamondlike-carbon (DLC) coating (photo) ejectors with an antitwist lock and many others All of these so-called standardized specials come in a wide range of stocked dimensions

The Rainer Knarr Group operates its own mould making division There-fore it well understands the needs and challenges of mould makers and

injection moulders The supplier sup-ports customers by offering a flexible ordering and deliv-ery servicemdashwith same-day shipping even for emergency orders received on Saturdaymdashan on-line shop and CAD data that is available for downloading

Always working on developing better solutions Rainer Knarr has recently launched several new product lines One is the huge XXL programme of flat ejector pins This line features pins in dimensions other than the well-known standard ones In addition it includes flat ejec-tors with corner radii and a DLC coat-ing flat ejectors with a long sheet and high-speed flat ejectors

Another line con-sists of patented hardened or nitrid-ed stepless ejector sleeves designed to facilitate reduction of the guide length

Also new from Rainer Knarr is a range of waved deflection baffles made of plastic which help ensure efficient balanced

mould cooling And the last highlight-ed recent introduction from the com-pany is a series of ejectors for outline pins that are made of hot-working steel hardened to 53 HRc for opti-mum machinability

Service-Oriented Supplier Provides Standard Mould Parts and Standardized Specials

raquo Rainer Knarr Vertriebs GmbHHelmbrechts Germanywwwrainer-knarrde

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

12

Industry News

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

In Sosnowiec Poland prepara-tions are in full swing for Toolex 2011 the International Machine Tools Tools and Processing Tech-nology Fair which is scheduled to take place October 5ndash7 at the Expo Silesia Exhibition Cen-tre This prestigious event for the metal-processing industry attracts more and more indus-try experts every year In 2010 more than 6000 professional and expert show visitors were very satisfied by what they found at the 167 exhibition stands showcasing over 350 companies from more than two dozen coun-tries around the world

Toolex always offers a compre-hensive presentation of machine tools specialized tools tech-nological equipment software and measuring and control instruments including world premieres of many machines and tools Last year in an exhibition area extending over more than 4000 m2 181 metal-processing machine tools on display were in full operation The venue is equipped to allow exhibitors to display large and

complex operating machines includ-ing entire assembly lines

The exhibition facility in Sosno wiec is situated in the heart of Polandrsquos most industrial region which is also an important scientific centre The area of Silesia and Zaglebie is home to a range of fast-growing industri-al sectors such as the automotive

aviation and mechanical engineer-ing industries among others Also the Czech Republic and Slovakia are nearby Transportation access to the venue is well developed

Expo Silesia Expects Toolex 2011 to Be Another Successful Metal-Processing Fair

raquo Toolex 2011Sosnowiec Polandwwwtoolexpl

MCH Swiss Exhibition (Basel) Ltd has handed over the organization and operation of Swisstech Europersquos Central Fair for the Subcontracting Industries to its wholly owned sub-sidiary Exhibit amp More AG The latter company now is in charge of Swiss-tech 2012 scheduled for November 20ndash23 2012 in Basel Exhibit amp More headquartered near Zuumlrich has been organizing specialist industrial fairs for more than 30 years

Swisstech is a key meeting point

The MCH Group assumed full con-trol of Exhibit amp More at the beginning of 2010 The managers of both trade fair organizing entities are convinced that the merger of their forces will make it possible to position Swisstech and Prodex in the market more effi-ciently and to steer a course toward a successful future

Swisstech Fair Henceforward in Hands of MCH Messe Basel Subsidiary Exhibit amp More

raquo Exhibit amp More AGFaumlllanden-Zuumlrich Switzerlandwwwexhibitandmorech

every two years for the subcontract-ing industry companies operating in the fields of procurement manu-facturing and production technolo-gy MCHmdashalso known as MCH Messe Baselmdashhas used Swisstech to high-light the synergies that exist between the mechanical engineering industry and the world of specialist suppliers It has also organized Prodex the spe-cialist exhibition for machine tools tools and production measurement in parallel with Swisstech since 2004

Who knocks PET bottles into shape

CorroPlastreg

ndash the ultimate steel forall-stainless mould sets

DEUTSCHE EDELSTAHLWERKE Obere Kaiserstr D-57078 Siegen Auestr 4 D-58452 Witten

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Industry News

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

Interactive Meusburger Catalogue Provides Free Standard Parts Calculation

Version 50 of the interactive CD catalogue issued by Meusburger the Austrian manufacturer of standard parts has many new features The catalogue software includes new products for mould making as well as the entire punching tool product range a recent addition to the Meusburger portfolio The company has prided itself on setting industry trends for digital catalogues and the advanced features in the latest CD version continue the customer-oriented tradition

The software is equipped with a mould assistant for injection moulding tools and a die-set assistant for punch-ing-tool construction Selecting various plates from a mod-ular system users can assemble mould tools and die sets with just a few clicks of the mouse The software then cal-culates all necessary accessories fully automatically and free of charge The CD catalogue includes 3D models of more than 46000 Meusburger products which are easily exported into all current CAD systems and as neutral data

By displaying individual prices for different customers the digital catalogue renders inquiries obsolete Also the integrated e-mail function makes ordering a faster and simpler process Useful search options and new group fil-ters (with pictures) help save time and effort in looking for products And finally an automatic update feature makes sure that users are working with the latest software and will not miss any newly introduced products

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo FIP Solution Plastique 2011Lyon Francewwwf-i-pcom

raquo Eberhard WerkzeugtechnologieNordheim Germanywwweberhardde

FIP 2011 Plastics Industry Exhibition Due in Lyon in May

Eberhard GmbH Enjoys a 28 Increase in Turnover in 2010

From May 24 to 27 the Rhocircne capital of Lyon will host FIP Solution Plastique 2011 the Plastics Industry Exhibition in France FIP is the only French trade show that brings all of the plastics industry players togeth-er in one place in this case the Lyon Eurexpo More than 500 exhibitors representing all aspects of the plas-tics industry will be on hand These include upstream suppliers of raw materials as well as producers or pro-viders of machines and equipment moulds and tools design services prototypes and models inspection technologies for quality control soft-ware and recycling technology Pro-cessors directly connected with final clients will be present in the area des-ignated FIPrsquoProjets

Because innovation is so important for companies wishing to stand out in

Gebruumlder Eberhard GmbH the par-ent company of the tool technology specialist Eberhard Werkzeugtech-nologie increased its turnover to just under euro90 million in 2010 a 28 rise Thus the company has managed to top the highest figure it had achieved before the period of economic crisis Meanwhile its staff increased by 10 last year to 440 employees

Eberhard GmbH manufactures stan-dard parts and accessories for tools in Nordheim and runs a specialized electrical retail outlet in Heilbronn as well as operating an additional tool technology production site in Thuringia and another electrical retail outlet in Saxony

Z 107101 Z 107105

The new universalneedle valvepermits the construction of compactmoulds and simplifies the integration of the needle valve systems in manyapplications

Unique flexibility in nozzle length and diameter

Can be used with all standard nozzles

Flexible valve pin strokeup to 7 mm

Available for 2 needle diameters (2 and 25 mm)

Flexible drive solutions Hydraulic internal or pneumatic external

No melt split in the diverting unit

Integration in stack and tandem moulds is possible

Minimum mounting space

HASCO Hasenclever GmbH+Co KGIm Wiesental 77 middot D-58513 LuumldenscheidTel +49 2351 957-0 middot Fax +49 2351 957-237E-mail infohascocom middot wwwhascocom

Together we shape your ideas

Improved colour change properties

the market FIP Solu-tion Plastique 2011 includes the Innova-tion Forum which offers a harmonized overview of recent industry develop-

ments Exhibitors in 15- to 20-minute speeches will unveil innovative solu-tions that resulted from advanced research and new technologies The trade fair also comprises a free con-ference programme and other edu-cational offerings to complement the Innovation Forum and FIPrsquoProjets

The 4th annual Caoutchouc Caucho Gomma international meeting of the rubber and polymer industries takes place at the same time as FIP Solution Plastique 2011 and also in the Lyon Eurexpo

The company benefited from the fact that it did not reduce its work-force in 2009 despite a significant decline in turnover In fact it made extensive investments and doubled the production area in Nordheim ldquoAfter all positive continuity is what sets down-to-earth family-owned companies apartrdquo says CEO Roland Eberhard Eberhard GmbH also expanded its vocational trainee pro-gramme and has signed contracts with a second generation of students at the Cooperative University

Industry News

16

Cover Story | Interview

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

A company with a strong pres-ence in Europe Meusburger

is a long-established specialist in the field of standard moulds In the past few years the Austrian enterprise has invested consider-able resources in expanding plant capacity in an effort to keep pace with its business growth Mean-while it introduced a completely new line of tool components to

enlarge an already bulging product catalogue

A strong position in the Euro-pean market is not alone enough for Meusburger Standard Moulds however The company founded a sales office in China in 2010 ETMM spoke with the companyrsquos managing director Guntram Meusburger son of the epony-mous founder about these and other aspects of Meusburgerrsquos present and future operations

ETMM Please give us a brief history of Meusburger GmbH How did the company start and how did it reach its present statureMeusburger ldquoConcentrating on our own strengthsrdquomdashthis slogan has been guiding Meusburger ever since 1964 The company started off as a one-man business and today employs 420 members of staff By continuously focusing on its own strengths clearly struc-tured processes the targeting of products to meet customer needs

and quality assurance Meusburg-er has become a European leader in the field of standard moulds which represents the companyrsquos main product line

Which industry sector is most impor-tant to your company and which sectors are you looking to develop furtherMeusburger stands for continu-ity and growthmdashand especially for high-quality products for the tool and mould making industry Last year we created space for some new things and we became very active in many other areas as well For example we prepared the introduction of a new field of businessmdashnamely punching tool

construction for which we have developed products We want to continue on this successful path in the coming year

We are particularly proud of our modular systemndashbased punch-ing-tool standard parts which are completely new However though these products are in fact new we have managed to adapt numerous well-known Meusburger advan-tages from our injection-mould-making range for use in construct-ing the punching tools

What recent or forthcoming new tech-nologies will bring your customers more value in the futureStress-relieved standard parts that is the obvious answer Playing a key role at the beginning of the process chain these components form a reliable foundation for high-quality moulds and tools The latest investment project of Meusburger has been additional furnaces with 120 tons of loading capacity per day With this invest-ment we increased the existing capacity by more than half

Stress-relieved standard parts in particular the parts for injec-tion moulds and punching dies offer many benefits to toolmak-ers We apply the stress-relieving

Concentrating on Strengths a Mould Industry Supplier GrowsMeusburger Standard Moulds has been successful for nearly half a century and its director suggests intends not to let up

ldquoMeusburger stands for continuity and growthmdashand especially for high-quality products for the tool and mould making industry We place great value on products that provide a clear added value for our customersrdquo

Managing Director Guntram Meusburger

wwwthebrightworldofmetalscom wwwgmtnde

One date ndash one place ndash four eventsMake the most of four high-calibre trade fairs ndash for foundry technology metallurgy thermo process technology and precision castings ndash in one place and with one entrance ticket

The industriesrsquo Number 1 worldwide multiple synergies connections and networks all in just one show visit Welcome to Duumlsseldorf

The Bright Worldof MetalsDuumlsseldorf Germany 28 June ndash 02 July 2011

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Interview

heat treatment to all grades of steel That is the best prerequisite for warp-free machining of parts

What do you consider to be Meusburgerrsquos most important product rangeManufacturing plates for injection moulding and punching tools clearly is our biggest strength in rela-tion to our competitors Meusburger uses the best raw materials and suppliers and we implement a programme of complete quality assurance through-out the production process

How important is research and development to Meus-burger Standard MouldsWe place great value on products that provide a clear added value for our customers Therefore we develop new products by working together with customers to fulfill not only their specific needs but also and especially the needs of the market generally

Is Meusburger GmbH active in AsiaIn 2010 we opened a new sales office in Wuxi China in Jiangsu Province The reason for that is that many of our customers have manufacturing operations in China and have expressed an inter-est in using standard products made by Meusburger there As a supplier of high-quality standard parts we naturally thought it was important for us to have an in-country sales office of our own

Incidentally from May 17 to May 20 this year Meusburger GmbH will be represented for the first time at the Chinaplas trade fair which is being held in the city of Guangzhou China We invite read-ers intending to visit that show to come see us at Stand D 41 in Hall 32

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

The investment of millions of euros in the Meusburger production facility in Wolfurt in recent years extended the companyrsquos capabilities For example new furnaces allow the standard parts manufacturer to produce stress-relieved components in greater volume

18

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Advanced series of customized hot runner systems a thoroughly innovative new solution

from DME has been designed to free mould makers from the limita-tions imposed by ldquohalf-

standardrdquo solutionsmdashthat is the use of standard

products to construct a special hot runner system

With the concept-products of the Advanced series the

moulder receives a fully cus-tomer-specific system tailored

to defined needs without any compromising that will perform

exactly as it should

This hot runner series was made possible by the development of sev-eral different nozzle tips with new openings These provide an opti-mal solution for every material and accommodate lateral-injection and multiple-gating requirements Within 24 hours of request DME will offer a quotation for a complex hot runner solution including a 3D drawing and a multiflow system if needed Deliv-ery of such a system can be expect-ed in 7 to 20 working days depend-ing on the complexity plus transport Expedited delivery also is available

raquo DME EuropeMechelen Belgiumwwwdmeeucom

Custom Hot Runners without Compromise Are Available via New System Solution

Rainer Knarr Vertriebs GmbH spe-cializes in the manufacture and sup-ply of standard and custom mould parts The company prides itself on including in its standards line mould accessories that other suppliers might offer only as specials

Beyond its extensive range of stan-dard components Rainer Knarr also provides custom mould components for tool and mould makers and injec-tion-moulders such as flat ejector pins with corner radius flat ejector pins with an extralong blade step-less sleeve ejectors pins that have a diamondlike-carbon (DLC) coating (photo) ejectors with an antitwist lock and many others All of these so-called standardized specials come in a wide range of stocked dimensions

The Rainer Knarr Group operates its own mould making division There-fore it well understands the needs and challenges of mould makers and

injection moulders The supplier sup-ports customers by offering a flexible ordering and deliv-ery servicemdashwith same-day shipping even for emergency orders received on Saturdaymdashan on-line shop and CAD data that is available for downloading

Always working on developing better solutions Rainer Knarr has recently launched several new product lines One is the huge XXL programme of flat ejector pins This line features pins in dimensions other than the well-known standard ones In addition it includes flat ejec-tors with corner radii and a DLC coat-ing flat ejectors with a long sheet and high-speed flat ejectors

Another line con-sists of patented hardened or nitrid-ed stepless ejector sleeves designed to facilitate reduction of the guide length

Also new from Rainer Knarr is a range of waved deflection baffles made of plastic which help ensure efficient balanced

mould cooling And the last highlight-ed recent introduction from the com-pany is a series of ejectors for outline pins that are made of hot-working steel hardened to 53 HRc for opti-mum machinability

Service-Oriented Supplier Provides Standard Mould Parts and Standardized Specials

raquo Rainer Knarr Vertriebs GmbHHelmbrechts Germanywwwrainer-knarrde

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

Who knocks PET bottles into shape

CorroPlastreg

ndash the ultimate steel forall-stainless mould sets

DEUTSCHE EDELSTAHLWERKE Obere Kaiserstr D-57078 Siegen Auestr 4 D-58452 Witten

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Industry News

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

Interactive Meusburger Catalogue Provides Free Standard Parts Calculation

Version 50 of the interactive CD catalogue issued by Meusburger the Austrian manufacturer of standard parts has many new features The catalogue software includes new products for mould making as well as the entire punching tool product range a recent addition to the Meusburger portfolio The company has prided itself on setting industry trends for digital catalogues and the advanced features in the latest CD version continue the customer-oriented tradition

The software is equipped with a mould assistant for injection moulding tools and a die-set assistant for punch-ing-tool construction Selecting various plates from a mod-ular system users can assemble mould tools and die sets with just a few clicks of the mouse The software then cal-culates all necessary accessories fully automatically and free of charge The CD catalogue includes 3D models of more than 46000 Meusburger products which are easily exported into all current CAD systems and as neutral data

By displaying individual prices for different customers the digital catalogue renders inquiries obsolete Also the integrated e-mail function makes ordering a faster and simpler process Useful search options and new group fil-ters (with pictures) help save time and effort in looking for products And finally an automatic update feature makes sure that users are working with the latest software and will not miss any newly introduced products

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo FIP Solution Plastique 2011Lyon Francewwwf-i-pcom

raquo Eberhard WerkzeugtechnologieNordheim Germanywwweberhardde

FIP 2011 Plastics Industry Exhibition Due in Lyon in May

Eberhard GmbH Enjoys a 28 Increase in Turnover in 2010

From May 24 to 27 the Rhocircne capital of Lyon will host FIP Solution Plastique 2011 the Plastics Industry Exhibition in France FIP is the only French trade show that brings all of the plastics industry players togeth-er in one place in this case the Lyon Eurexpo More than 500 exhibitors representing all aspects of the plas-tics industry will be on hand These include upstream suppliers of raw materials as well as producers or pro-viders of machines and equipment moulds and tools design services prototypes and models inspection technologies for quality control soft-ware and recycling technology Pro-cessors directly connected with final clients will be present in the area des-ignated FIPrsquoProjets

Because innovation is so important for companies wishing to stand out in

Gebruumlder Eberhard GmbH the par-ent company of the tool technology specialist Eberhard Werkzeugtech-nologie increased its turnover to just under euro90 million in 2010 a 28 rise Thus the company has managed to top the highest figure it had achieved before the period of economic crisis Meanwhile its staff increased by 10 last year to 440 employees

Eberhard GmbH manufactures stan-dard parts and accessories for tools in Nordheim and runs a specialized electrical retail outlet in Heilbronn as well as operating an additional tool technology production site in Thuringia and another electrical retail outlet in Saxony

Z 107101 Z 107105

The new universalneedle valvepermits the construction of compactmoulds and simplifies the integration of the needle valve systems in manyapplications

Unique flexibility in nozzle length and diameter

Can be used with all standard nozzles

Flexible valve pin strokeup to 7 mm

Available for 2 needle diameters (2 and 25 mm)

Flexible drive solutions Hydraulic internal or pneumatic external

No melt split in the diverting unit

Integration in stack and tandem moulds is possible

Minimum mounting space

HASCO Hasenclever GmbH+Co KGIm Wiesental 77 middot D-58513 LuumldenscheidTel +49 2351 957-0 middot Fax +49 2351 957-237E-mail infohascocom middot wwwhascocom

Together we shape your ideas

Improved colour change properties

the market FIP Solu-tion Plastique 2011 includes the Innova-tion Forum which offers a harmonized overview of recent industry develop-

ments Exhibitors in 15- to 20-minute speeches will unveil innovative solu-tions that resulted from advanced research and new technologies The trade fair also comprises a free con-ference programme and other edu-cational offerings to complement the Innovation Forum and FIPrsquoProjets

The 4th annual Caoutchouc Caucho Gomma international meeting of the rubber and polymer industries takes place at the same time as FIP Solution Plastique 2011 and also in the Lyon Eurexpo

The company benefited from the fact that it did not reduce its work-force in 2009 despite a significant decline in turnover In fact it made extensive investments and doubled the production area in Nordheim ldquoAfter all positive continuity is what sets down-to-earth family-owned companies apartrdquo says CEO Roland Eberhard Eberhard GmbH also expanded its vocational trainee pro-gramme and has signed contracts with a second generation of students at the Cooperative University

Industry News

16

Cover Story | Interview

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

A company with a strong pres-ence in Europe Meusburger

is a long-established specialist in the field of standard moulds In the past few years the Austrian enterprise has invested consider-able resources in expanding plant capacity in an effort to keep pace with its business growth Mean-while it introduced a completely new line of tool components to

enlarge an already bulging product catalogue

A strong position in the Euro-pean market is not alone enough for Meusburger Standard Moulds however The company founded a sales office in China in 2010 ETMM spoke with the companyrsquos managing director Guntram Meusburger son of the epony-mous founder about these and other aspects of Meusburgerrsquos present and future operations

ETMM Please give us a brief history of Meusburger GmbH How did the company start and how did it reach its present statureMeusburger ldquoConcentrating on our own strengthsrdquomdashthis slogan has been guiding Meusburger ever since 1964 The company started off as a one-man business and today employs 420 members of staff By continuously focusing on its own strengths clearly struc-tured processes the targeting of products to meet customer needs

and quality assurance Meusburg-er has become a European leader in the field of standard moulds which represents the companyrsquos main product line

Which industry sector is most impor-tant to your company and which sectors are you looking to develop furtherMeusburger stands for continu-ity and growthmdashand especially for high-quality products for the tool and mould making industry Last year we created space for some new things and we became very active in many other areas as well For example we prepared the introduction of a new field of businessmdashnamely punching tool

construction for which we have developed products We want to continue on this successful path in the coming year

We are particularly proud of our modular systemndashbased punch-ing-tool standard parts which are completely new However though these products are in fact new we have managed to adapt numerous well-known Meusburger advan-tages from our injection-mould-making range for use in construct-ing the punching tools

What recent or forthcoming new tech-nologies will bring your customers more value in the futureStress-relieved standard parts that is the obvious answer Playing a key role at the beginning of the process chain these components form a reliable foundation for high-quality moulds and tools The latest investment project of Meusburger has been additional furnaces with 120 tons of loading capacity per day With this invest-ment we increased the existing capacity by more than half

Stress-relieved standard parts in particular the parts for injec-tion moulds and punching dies offer many benefits to toolmak-ers We apply the stress-relieving

Concentrating on Strengths a Mould Industry Supplier GrowsMeusburger Standard Moulds has been successful for nearly half a century and its director suggests intends not to let up

ldquoMeusburger stands for continuity and growthmdashand especially for high-quality products for the tool and mould making industry We place great value on products that provide a clear added value for our customersrdquo

Managing Director Guntram Meusburger

wwwthebrightworldofmetalscom wwwgmtnde

One date ndash one place ndash four eventsMake the most of four high-calibre trade fairs ndash for foundry technology metallurgy thermo process technology and precision castings ndash in one place and with one entrance ticket

The industriesrsquo Number 1 worldwide multiple synergies connections and networks all in just one show visit Welcome to Duumlsseldorf

The Bright Worldof MetalsDuumlsseldorf Germany 28 June ndash 02 July 2011

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Interview

heat treatment to all grades of steel That is the best prerequisite for warp-free machining of parts

What do you consider to be Meusburgerrsquos most important product rangeManufacturing plates for injection moulding and punching tools clearly is our biggest strength in rela-tion to our competitors Meusburger uses the best raw materials and suppliers and we implement a programme of complete quality assurance through-out the production process

How important is research and development to Meus-burger Standard MouldsWe place great value on products that provide a clear added value for our customers Therefore we develop new products by working together with customers to fulfill not only their specific needs but also and especially the needs of the market generally

Is Meusburger GmbH active in AsiaIn 2010 we opened a new sales office in Wuxi China in Jiangsu Province The reason for that is that many of our customers have manufacturing operations in China and have expressed an inter-est in using standard products made by Meusburger there As a supplier of high-quality standard parts we naturally thought it was important for us to have an in-country sales office of our own

Incidentally from May 17 to May 20 this year Meusburger GmbH will be represented for the first time at the Chinaplas trade fair which is being held in the city of Guangzhou China We invite read-ers intending to visit that show to come see us at Stand D 41 in Hall 32

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

The investment of millions of euros in the Meusburger production facility in Wolfurt in recent years extended the companyrsquos capabilities For example new furnaces allow the standard parts manufacturer to produce stress-relieved components in greater volume

18

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Advanced series of customized hot runner systems a thoroughly innovative new solution

from DME has been designed to free mould makers from the limita-tions imposed by ldquohalf-

standardrdquo solutionsmdashthat is the use of standard

products to construct a special hot runner system

With the concept-products of the Advanced series the

moulder receives a fully cus-tomer-specific system tailored

to defined needs without any compromising that will perform

exactly as it should

This hot runner series was made possible by the development of sev-eral different nozzle tips with new openings These provide an opti-mal solution for every material and accommodate lateral-injection and multiple-gating requirements Within 24 hours of request DME will offer a quotation for a complex hot runner solution including a 3D drawing and a multiflow system if needed Deliv-ery of such a system can be expect-ed in 7 to 20 working days depend-ing on the complexity plus transport Expedited delivery also is available

raquo DME EuropeMechelen Belgiumwwwdmeeucom

Custom Hot Runners without Compromise Are Available via New System Solution

Rainer Knarr Vertriebs GmbH spe-cializes in the manufacture and sup-ply of standard and custom mould parts The company prides itself on including in its standards line mould accessories that other suppliers might offer only as specials

Beyond its extensive range of stan-dard components Rainer Knarr also provides custom mould components for tool and mould makers and injec-tion-moulders such as flat ejector pins with corner radius flat ejector pins with an extralong blade step-less sleeve ejectors pins that have a diamondlike-carbon (DLC) coating (photo) ejectors with an antitwist lock and many others All of these so-called standardized specials come in a wide range of stocked dimensions

The Rainer Knarr Group operates its own mould making division There-fore it well understands the needs and challenges of mould makers and

injection moulders The supplier sup-ports customers by offering a flexible ordering and deliv-ery servicemdashwith same-day shipping even for emergency orders received on Saturdaymdashan on-line shop and CAD data that is available for downloading

Always working on developing better solutions Rainer Knarr has recently launched several new product lines One is the huge XXL programme of flat ejector pins This line features pins in dimensions other than the well-known standard ones In addition it includes flat ejec-tors with corner radii and a DLC coat-ing flat ejectors with a long sheet and high-speed flat ejectors

Another line con-sists of patented hardened or nitrid-ed stepless ejector sleeves designed to facilitate reduction of the guide length

Also new from Rainer Knarr is a range of waved deflection baffles made of plastic which help ensure efficient balanced

mould cooling And the last highlight-ed recent introduction from the com-pany is a series of ejectors for outline pins that are made of hot-working steel hardened to 53 HRc for opti-mum machinability

Service-Oriented Supplier Provides Standard Mould Parts and Standardized Specials

raquo Rainer Knarr Vertriebs GmbHHelmbrechts Germanywwwrainer-knarrde

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Industry News

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

Interactive Meusburger Catalogue Provides Free Standard Parts Calculation

Version 50 of the interactive CD catalogue issued by Meusburger the Austrian manufacturer of standard parts has many new features The catalogue software includes new products for mould making as well as the entire punching tool product range a recent addition to the Meusburger portfolio The company has prided itself on setting industry trends for digital catalogues and the advanced features in the latest CD version continue the customer-oriented tradition

The software is equipped with a mould assistant for injection moulding tools and a die-set assistant for punch-ing-tool construction Selecting various plates from a mod-ular system users can assemble mould tools and die sets with just a few clicks of the mouse The software then cal-culates all necessary accessories fully automatically and free of charge The CD catalogue includes 3D models of more than 46000 Meusburger products which are easily exported into all current CAD systems and as neutral data

By displaying individual prices for different customers the digital catalogue renders inquiries obsolete Also the integrated e-mail function makes ordering a faster and simpler process Useful search options and new group fil-ters (with pictures) help save time and effort in looking for products And finally an automatic update feature makes sure that users are working with the latest software and will not miss any newly introduced products

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo FIP Solution Plastique 2011Lyon Francewwwf-i-pcom

raquo Eberhard WerkzeugtechnologieNordheim Germanywwweberhardde

FIP 2011 Plastics Industry Exhibition Due in Lyon in May

Eberhard GmbH Enjoys a 28 Increase in Turnover in 2010

From May 24 to 27 the Rhocircne capital of Lyon will host FIP Solution Plastique 2011 the Plastics Industry Exhibition in France FIP is the only French trade show that brings all of the plastics industry players togeth-er in one place in this case the Lyon Eurexpo More than 500 exhibitors representing all aspects of the plas-tics industry will be on hand These include upstream suppliers of raw materials as well as producers or pro-viders of machines and equipment moulds and tools design services prototypes and models inspection technologies for quality control soft-ware and recycling technology Pro-cessors directly connected with final clients will be present in the area des-ignated FIPrsquoProjets

Because innovation is so important for companies wishing to stand out in

Gebruumlder Eberhard GmbH the par-ent company of the tool technology specialist Eberhard Werkzeugtech-nologie increased its turnover to just under euro90 million in 2010 a 28 rise Thus the company has managed to top the highest figure it had achieved before the period of economic crisis Meanwhile its staff increased by 10 last year to 440 employees

Eberhard GmbH manufactures stan-dard parts and accessories for tools in Nordheim and runs a specialized electrical retail outlet in Heilbronn as well as operating an additional tool technology production site in Thuringia and another electrical retail outlet in Saxony

Z 107101 Z 107105

The new universalneedle valvepermits the construction of compactmoulds and simplifies the integration of the needle valve systems in manyapplications

Unique flexibility in nozzle length and diameter

Can be used with all standard nozzles

Flexible valve pin strokeup to 7 mm

Available for 2 needle diameters (2 and 25 mm)

Flexible drive solutions Hydraulic internal or pneumatic external

No melt split in the diverting unit

Integration in stack and tandem moulds is possible

Minimum mounting space

HASCO Hasenclever GmbH+Co KGIm Wiesental 77 middot D-58513 LuumldenscheidTel +49 2351 957-0 middot Fax +49 2351 957-237E-mail infohascocom middot wwwhascocom

Together we shape your ideas

Improved colour change properties

the market FIP Solu-tion Plastique 2011 includes the Innova-tion Forum which offers a harmonized overview of recent industry develop-

ments Exhibitors in 15- to 20-minute speeches will unveil innovative solu-tions that resulted from advanced research and new technologies The trade fair also comprises a free con-ference programme and other edu-cational offerings to complement the Innovation Forum and FIPrsquoProjets

The 4th annual Caoutchouc Caucho Gomma international meeting of the rubber and polymer industries takes place at the same time as FIP Solution Plastique 2011 and also in the Lyon Eurexpo

The company benefited from the fact that it did not reduce its work-force in 2009 despite a significant decline in turnover In fact it made extensive investments and doubled the production area in Nordheim ldquoAfter all positive continuity is what sets down-to-earth family-owned companies apartrdquo says CEO Roland Eberhard Eberhard GmbH also expanded its vocational trainee pro-gramme and has signed contracts with a second generation of students at the Cooperative University

Industry News

16

Cover Story | Interview

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

A company with a strong pres-ence in Europe Meusburger

is a long-established specialist in the field of standard moulds In the past few years the Austrian enterprise has invested consider-able resources in expanding plant capacity in an effort to keep pace with its business growth Mean-while it introduced a completely new line of tool components to

enlarge an already bulging product catalogue

A strong position in the Euro-pean market is not alone enough for Meusburger Standard Moulds however The company founded a sales office in China in 2010 ETMM spoke with the companyrsquos managing director Guntram Meusburger son of the epony-mous founder about these and other aspects of Meusburgerrsquos present and future operations

ETMM Please give us a brief history of Meusburger GmbH How did the company start and how did it reach its present statureMeusburger ldquoConcentrating on our own strengthsrdquomdashthis slogan has been guiding Meusburger ever since 1964 The company started off as a one-man business and today employs 420 members of staff By continuously focusing on its own strengths clearly struc-tured processes the targeting of products to meet customer needs

and quality assurance Meusburg-er has become a European leader in the field of standard moulds which represents the companyrsquos main product line

Which industry sector is most impor-tant to your company and which sectors are you looking to develop furtherMeusburger stands for continu-ity and growthmdashand especially for high-quality products for the tool and mould making industry Last year we created space for some new things and we became very active in many other areas as well For example we prepared the introduction of a new field of businessmdashnamely punching tool

construction for which we have developed products We want to continue on this successful path in the coming year

We are particularly proud of our modular systemndashbased punch-ing-tool standard parts which are completely new However though these products are in fact new we have managed to adapt numerous well-known Meusburger advan-tages from our injection-mould-making range for use in construct-ing the punching tools

What recent or forthcoming new tech-nologies will bring your customers more value in the futureStress-relieved standard parts that is the obvious answer Playing a key role at the beginning of the process chain these components form a reliable foundation for high-quality moulds and tools The latest investment project of Meusburger has been additional furnaces with 120 tons of loading capacity per day With this invest-ment we increased the existing capacity by more than half

Stress-relieved standard parts in particular the parts for injec-tion moulds and punching dies offer many benefits to toolmak-ers We apply the stress-relieving

Concentrating on Strengths a Mould Industry Supplier GrowsMeusburger Standard Moulds has been successful for nearly half a century and its director suggests intends not to let up

ldquoMeusburger stands for continuity and growthmdashand especially for high-quality products for the tool and mould making industry We place great value on products that provide a clear added value for our customersrdquo

Managing Director Guntram Meusburger

wwwthebrightworldofmetalscom wwwgmtnde

One date ndash one place ndash four eventsMake the most of four high-calibre trade fairs ndash for foundry technology metallurgy thermo process technology and precision castings ndash in one place and with one entrance ticket

The industriesrsquo Number 1 worldwide multiple synergies connections and networks all in just one show visit Welcome to Duumlsseldorf

The Bright Worldof MetalsDuumlsseldorf Germany 28 June ndash 02 July 2011

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Interview

heat treatment to all grades of steel That is the best prerequisite for warp-free machining of parts

What do you consider to be Meusburgerrsquos most important product rangeManufacturing plates for injection moulding and punching tools clearly is our biggest strength in rela-tion to our competitors Meusburger uses the best raw materials and suppliers and we implement a programme of complete quality assurance through-out the production process

How important is research and development to Meus-burger Standard MouldsWe place great value on products that provide a clear added value for our customers Therefore we develop new products by working together with customers to fulfill not only their specific needs but also and especially the needs of the market generally

Is Meusburger GmbH active in AsiaIn 2010 we opened a new sales office in Wuxi China in Jiangsu Province The reason for that is that many of our customers have manufacturing operations in China and have expressed an inter-est in using standard products made by Meusburger there As a supplier of high-quality standard parts we naturally thought it was important for us to have an in-country sales office of our own

Incidentally from May 17 to May 20 this year Meusburger GmbH will be represented for the first time at the Chinaplas trade fair which is being held in the city of Guangzhou China We invite read-ers intending to visit that show to come see us at Stand D 41 in Hall 32

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

The investment of millions of euros in the Meusburger production facility in Wolfurt in recent years extended the companyrsquos capabilities For example new furnaces allow the standard parts manufacturer to produce stress-relieved components in greater volume

18

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Advanced series of customized hot runner systems a thoroughly innovative new solution

from DME has been designed to free mould makers from the limita-tions imposed by ldquohalf-

standardrdquo solutionsmdashthat is the use of standard

products to construct a special hot runner system

With the concept-products of the Advanced series the

moulder receives a fully cus-tomer-specific system tailored

to defined needs without any compromising that will perform

exactly as it should

This hot runner series was made possible by the development of sev-eral different nozzle tips with new openings These provide an opti-mal solution for every material and accommodate lateral-injection and multiple-gating requirements Within 24 hours of request DME will offer a quotation for a complex hot runner solution including a 3D drawing and a multiflow system if needed Deliv-ery of such a system can be expect-ed in 7 to 20 working days depend-ing on the complexity plus transport Expedited delivery also is available

raquo DME EuropeMechelen Belgiumwwwdmeeucom

Custom Hot Runners without Compromise Are Available via New System Solution

Rainer Knarr Vertriebs GmbH spe-cializes in the manufacture and sup-ply of standard and custom mould parts The company prides itself on including in its standards line mould accessories that other suppliers might offer only as specials

Beyond its extensive range of stan-dard components Rainer Knarr also provides custom mould components for tool and mould makers and injec-tion-moulders such as flat ejector pins with corner radius flat ejector pins with an extralong blade step-less sleeve ejectors pins that have a diamondlike-carbon (DLC) coating (photo) ejectors with an antitwist lock and many others All of these so-called standardized specials come in a wide range of stocked dimensions

The Rainer Knarr Group operates its own mould making division There-fore it well understands the needs and challenges of mould makers and

injection moulders The supplier sup-ports customers by offering a flexible ordering and deliv-ery servicemdashwith same-day shipping even for emergency orders received on Saturdaymdashan on-line shop and CAD data that is available for downloading

Always working on developing better solutions Rainer Knarr has recently launched several new product lines One is the huge XXL programme of flat ejector pins This line features pins in dimensions other than the well-known standard ones In addition it includes flat ejec-tors with corner radii and a DLC coat-ing flat ejectors with a long sheet and high-speed flat ejectors

Another line con-sists of patented hardened or nitrid-ed stepless ejector sleeves designed to facilitate reduction of the guide length

Also new from Rainer Knarr is a range of waved deflection baffles made of plastic which help ensure efficient balanced

mould cooling And the last highlight-ed recent introduction from the com-pany is a series of ejectors for outline pins that are made of hot-working steel hardened to 53 HRc for opti-mum machinability

Service-Oriented Supplier Provides Standard Mould Parts and Standardized Specials

raquo Rainer Knarr Vertriebs GmbHHelmbrechts Germanywwwrainer-knarrde

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo FIP Solution Plastique 2011Lyon Francewwwf-i-pcom

raquo Eberhard WerkzeugtechnologieNordheim Germanywwweberhardde

FIP 2011 Plastics Industry Exhibition Due in Lyon in May

Eberhard GmbH Enjoys a 28 Increase in Turnover in 2010

From May 24 to 27 the Rhocircne capital of Lyon will host FIP Solution Plastique 2011 the Plastics Industry Exhibition in France FIP is the only French trade show that brings all of the plastics industry players togeth-er in one place in this case the Lyon Eurexpo More than 500 exhibitors representing all aspects of the plas-tics industry will be on hand These include upstream suppliers of raw materials as well as producers or pro-viders of machines and equipment moulds and tools design services prototypes and models inspection technologies for quality control soft-ware and recycling technology Pro-cessors directly connected with final clients will be present in the area des-ignated FIPrsquoProjets

Because innovation is so important for companies wishing to stand out in

Gebruumlder Eberhard GmbH the par-ent company of the tool technology specialist Eberhard Werkzeugtech-nologie increased its turnover to just under euro90 million in 2010 a 28 rise Thus the company has managed to top the highest figure it had achieved before the period of economic crisis Meanwhile its staff increased by 10 last year to 440 employees

Eberhard GmbH manufactures stan-dard parts and accessories for tools in Nordheim and runs a specialized electrical retail outlet in Heilbronn as well as operating an additional tool technology production site in Thuringia and another electrical retail outlet in Saxony

Z 107101 Z 107105

The new universalneedle valvepermits the construction of compactmoulds and simplifies the integration of the needle valve systems in manyapplications

Unique flexibility in nozzle length and diameter

Can be used with all standard nozzles

Flexible valve pin strokeup to 7 mm

Available for 2 needle diameters (2 and 25 mm)

Flexible drive solutions Hydraulic internal or pneumatic external

No melt split in the diverting unit

Integration in stack and tandem moulds is possible

Minimum mounting space

HASCO Hasenclever GmbH+Co KGIm Wiesental 77 middot D-58513 LuumldenscheidTel +49 2351 957-0 middot Fax +49 2351 957-237E-mail infohascocom middot wwwhascocom

Together we shape your ideas

Improved colour change properties

the market FIP Solu-tion Plastique 2011 includes the Innova-tion Forum which offers a harmonized overview of recent industry develop-

ments Exhibitors in 15- to 20-minute speeches will unveil innovative solu-tions that resulted from advanced research and new technologies The trade fair also comprises a free con-ference programme and other edu-cational offerings to complement the Innovation Forum and FIPrsquoProjets

The 4th annual Caoutchouc Caucho Gomma international meeting of the rubber and polymer industries takes place at the same time as FIP Solution Plastique 2011 and also in the Lyon Eurexpo

The company benefited from the fact that it did not reduce its work-force in 2009 despite a significant decline in turnover In fact it made extensive investments and doubled the production area in Nordheim ldquoAfter all positive continuity is what sets down-to-earth family-owned companies apartrdquo says CEO Roland Eberhard Eberhard GmbH also expanded its vocational trainee pro-gramme and has signed contracts with a second generation of students at the Cooperative University

Industry News

16

Cover Story | Interview

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

A company with a strong pres-ence in Europe Meusburger

is a long-established specialist in the field of standard moulds In the past few years the Austrian enterprise has invested consider-able resources in expanding plant capacity in an effort to keep pace with its business growth Mean-while it introduced a completely new line of tool components to

enlarge an already bulging product catalogue

A strong position in the Euro-pean market is not alone enough for Meusburger Standard Moulds however The company founded a sales office in China in 2010 ETMM spoke with the companyrsquos managing director Guntram Meusburger son of the epony-mous founder about these and other aspects of Meusburgerrsquos present and future operations

ETMM Please give us a brief history of Meusburger GmbH How did the company start and how did it reach its present statureMeusburger ldquoConcentrating on our own strengthsrdquomdashthis slogan has been guiding Meusburger ever since 1964 The company started off as a one-man business and today employs 420 members of staff By continuously focusing on its own strengths clearly struc-tured processes the targeting of products to meet customer needs

and quality assurance Meusburg-er has become a European leader in the field of standard moulds which represents the companyrsquos main product line

Which industry sector is most impor-tant to your company and which sectors are you looking to develop furtherMeusburger stands for continu-ity and growthmdashand especially for high-quality products for the tool and mould making industry Last year we created space for some new things and we became very active in many other areas as well For example we prepared the introduction of a new field of businessmdashnamely punching tool

construction for which we have developed products We want to continue on this successful path in the coming year

We are particularly proud of our modular systemndashbased punch-ing-tool standard parts which are completely new However though these products are in fact new we have managed to adapt numerous well-known Meusburger advan-tages from our injection-mould-making range for use in construct-ing the punching tools

What recent or forthcoming new tech-nologies will bring your customers more value in the futureStress-relieved standard parts that is the obvious answer Playing a key role at the beginning of the process chain these components form a reliable foundation for high-quality moulds and tools The latest investment project of Meusburger has been additional furnaces with 120 tons of loading capacity per day With this invest-ment we increased the existing capacity by more than half

Stress-relieved standard parts in particular the parts for injec-tion moulds and punching dies offer many benefits to toolmak-ers We apply the stress-relieving

Concentrating on Strengths a Mould Industry Supplier GrowsMeusburger Standard Moulds has been successful for nearly half a century and its director suggests intends not to let up

ldquoMeusburger stands for continuity and growthmdashand especially for high-quality products for the tool and mould making industry We place great value on products that provide a clear added value for our customersrdquo

Managing Director Guntram Meusburger

wwwthebrightworldofmetalscom wwwgmtnde

One date ndash one place ndash four eventsMake the most of four high-calibre trade fairs ndash for foundry technology metallurgy thermo process technology and precision castings ndash in one place and with one entrance ticket

The industriesrsquo Number 1 worldwide multiple synergies connections and networks all in just one show visit Welcome to Duumlsseldorf

The Bright Worldof MetalsDuumlsseldorf Germany 28 June ndash 02 July 2011

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Interview

heat treatment to all grades of steel That is the best prerequisite for warp-free machining of parts

What do you consider to be Meusburgerrsquos most important product rangeManufacturing plates for injection moulding and punching tools clearly is our biggest strength in rela-tion to our competitors Meusburger uses the best raw materials and suppliers and we implement a programme of complete quality assurance through-out the production process

How important is research and development to Meus-burger Standard MouldsWe place great value on products that provide a clear added value for our customers Therefore we develop new products by working together with customers to fulfill not only their specific needs but also and especially the needs of the market generally

Is Meusburger GmbH active in AsiaIn 2010 we opened a new sales office in Wuxi China in Jiangsu Province The reason for that is that many of our customers have manufacturing operations in China and have expressed an inter-est in using standard products made by Meusburger there As a supplier of high-quality standard parts we naturally thought it was important for us to have an in-country sales office of our own

Incidentally from May 17 to May 20 this year Meusburger GmbH will be represented for the first time at the Chinaplas trade fair which is being held in the city of Guangzhou China We invite read-ers intending to visit that show to come see us at Stand D 41 in Hall 32

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

The investment of millions of euros in the Meusburger production facility in Wolfurt in recent years extended the companyrsquos capabilities For example new furnaces allow the standard parts manufacturer to produce stress-relieved components in greater volume

18

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Advanced series of customized hot runner systems a thoroughly innovative new solution

from DME has been designed to free mould makers from the limita-tions imposed by ldquohalf-

standardrdquo solutionsmdashthat is the use of standard

products to construct a special hot runner system

With the concept-products of the Advanced series the

moulder receives a fully cus-tomer-specific system tailored

to defined needs without any compromising that will perform

exactly as it should

This hot runner series was made possible by the development of sev-eral different nozzle tips with new openings These provide an opti-mal solution for every material and accommodate lateral-injection and multiple-gating requirements Within 24 hours of request DME will offer a quotation for a complex hot runner solution including a 3D drawing and a multiflow system if needed Deliv-ery of such a system can be expect-ed in 7 to 20 working days depend-ing on the complexity plus transport Expedited delivery also is available

raquo DME EuropeMechelen Belgiumwwwdmeeucom

Custom Hot Runners without Compromise Are Available via New System Solution

Rainer Knarr Vertriebs GmbH spe-cializes in the manufacture and sup-ply of standard and custom mould parts The company prides itself on including in its standards line mould accessories that other suppliers might offer only as specials

Beyond its extensive range of stan-dard components Rainer Knarr also provides custom mould components for tool and mould makers and injec-tion-moulders such as flat ejector pins with corner radius flat ejector pins with an extralong blade step-less sleeve ejectors pins that have a diamondlike-carbon (DLC) coating (photo) ejectors with an antitwist lock and many others All of these so-called standardized specials come in a wide range of stocked dimensions

The Rainer Knarr Group operates its own mould making division There-fore it well understands the needs and challenges of mould makers and

injection moulders The supplier sup-ports customers by offering a flexible ordering and deliv-ery servicemdashwith same-day shipping even for emergency orders received on Saturdaymdashan on-line shop and CAD data that is available for downloading

Always working on developing better solutions Rainer Knarr has recently launched several new product lines One is the huge XXL programme of flat ejector pins This line features pins in dimensions other than the well-known standard ones In addition it includes flat ejec-tors with corner radii and a DLC coat-ing flat ejectors with a long sheet and high-speed flat ejectors

Another line con-sists of patented hardened or nitrid-ed stepless ejector sleeves designed to facilitate reduction of the guide length

Also new from Rainer Knarr is a range of waved deflection baffles made of plastic which help ensure efficient balanced

mould cooling And the last highlight-ed recent introduction from the com-pany is a series of ejectors for outline pins that are made of hot-working steel hardened to 53 HRc for opti-mum machinability

Service-Oriented Supplier Provides Standard Mould Parts and Standardized Specials

raquo Rainer Knarr Vertriebs GmbHHelmbrechts Germanywwwrainer-knarrde

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

16

Cover Story | Interview

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

A company with a strong pres-ence in Europe Meusburger

is a long-established specialist in the field of standard moulds In the past few years the Austrian enterprise has invested consider-able resources in expanding plant capacity in an effort to keep pace with its business growth Mean-while it introduced a completely new line of tool components to

enlarge an already bulging product catalogue

A strong position in the Euro-pean market is not alone enough for Meusburger Standard Moulds however The company founded a sales office in China in 2010 ETMM spoke with the companyrsquos managing director Guntram Meusburger son of the epony-mous founder about these and other aspects of Meusburgerrsquos present and future operations

ETMM Please give us a brief history of Meusburger GmbH How did the company start and how did it reach its present statureMeusburger ldquoConcentrating on our own strengthsrdquomdashthis slogan has been guiding Meusburger ever since 1964 The company started off as a one-man business and today employs 420 members of staff By continuously focusing on its own strengths clearly struc-tured processes the targeting of products to meet customer needs

and quality assurance Meusburg-er has become a European leader in the field of standard moulds which represents the companyrsquos main product line

Which industry sector is most impor-tant to your company and which sectors are you looking to develop furtherMeusburger stands for continu-ity and growthmdashand especially for high-quality products for the tool and mould making industry Last year we created space for some new things and we became very active in many other areas as well For example we prepared the introduction of a new field of businessmdashnamely punching tool

construction for which we have developed products We want to continue on this successful path in the coming year

We are particularly proud of our modular systemndashbased punch-ing-tool standard parts which are completely new However though these products are in fact new we have managed to adapt numerous well-known Meusburger advan-tages from our injection-mould-making range for use in construct-ing the punching tools

What recent or forthcoming new tech-nologies will bring your customers more value in the futureStress-relieved standard parts that is the obvious answer Playing a key role at the beginning of the process chain these components form a reliable foundation for high-quality moulds and tools The latest investment project of Meusburger has been additional furnaces with 120 tons of loading capacity per day With this invest-ment we increased the existing capacity by more than half

Stress-relieved standard parts in particular the parts for injec-tion moulds and punching dies offer many benefits to toolmak-ers We apply the stress-relieving

Concentrating on Strengths a Mould Industry Supplier GrowsMeusburger Standard Moulds has been successful for nearly half a century and its director suggests intends not to let up

ldquoMeusburger stands for continuity and growthmdashand especially for high-quality products for the tool and mould making industry We place great value on products that provide a clear added value for our customersrdquo

Managing Director Guntram Meusburger

wwwthebrightworldofmetalscom wwwgmtnde

One date ndash one place ndash four eventsMake the most of four high-calibre trade fairs ndash for foundry technology metallurgy thermo process technology and precision castings ndash in one place and with one entrance ticket

The industriesrsquo Number 1 worldwide multiple synergies connections and networks all in just one show visit Welcome to Duumlsseldorf

The Bright Worldof MetalsDuumlsseldorf Germany 28 June ndash 02 July 2011

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Interview

heat treatment to all grades of steel That is the best prerequisite for warp-free machining of parts

What do you consider to be Meusburgerrsquos most important product rangeManufacturing plates for injection moulding and punching tools clearly is our biggest strength in rela-tion to our competitors Meusburger uses the best raw materials and suppliers and we implement a programme of complete quality assurance through-out the production process

How important is research and development to Meus-burger Standard MouldsWe place great value on products that provide a clear added value for our customers Therefore we develop new products by working together with customers to fulfill not only their specific needs but also and especially the needs of the market generally

Is Meusburger GmbH active in AsiaIn 2010 we opened a new sales office in Wuxi China in Jiangsu Province The reason for that is that many of our customers have manufacturing operations in China and have expressed an inter-est in using standard products made by Meusburger there As a supplier of high-quality standard parts we naturally thought it was important for us to have an in-country sales office of our own

Incidentally from May 17 to May 20 this year Meusburger GmbH will be represented for the first time at the Chinaplas trade fair which is being held in the city of Guangzhou China We invite read-ers intending to visit that show to come see us at Stand D 41 in Hall 32

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

The investment of millions of euros in the Meusburger production facility in Wolfurt in recent years extended the companyrsquos capabilities For example new furnaces allow the standard parts manufacturer to produce stress-relieved components in greater volume

18

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Advanced series of customized hot runner systems a thoroughly innovative new solution

from DME has been designed to free mould makers from the limita-tions imposed by ldquohalf-

standardrdquo solutionsmdashthat is the use of standard

products to construct a special hot runner system

With the concept-products of the Advanced series the

moulder receives a fully cus-tomer-specific system tailored

to defined needs without any compromising that will perform

exactly as it should

This hot runner series was made possible by the development of sev-eral different nozzle tips with new openings These provide an opti-mal solution for every material and accommodate lateral-injection and multiple-gating requirements Within 24 hours of request DME will offer a quotation for a complex hot runner solution including a 3D drawing and a multiflow system if needed Deliv-ery of such a system can be expect-ed in 7 to 20 working days depend-ing on the complexity plus transport Expedited delivery also is available

raquo DME EuropeMechelen Belgiumwwwdmeeucom

Custom Hot Runners without Compromise Are Available via New System Solution

Rainer Knarr Vertriebs GmbH spe-cializes in the manufacture and sup-ply of standard and custom mould parts The company prides itself on including in its standards line mould accessories that other suppliers might offer only as specials

Beyond its extensive range of stan-dard components Rainer Knarr also provides custom mould components for tool and mould makers and injec-tion-moulders such as flat ejector pins with corner radius flat ejector pins with an extralong blade step-less sleeve ejectors pins that have a diamondlike-carbon (DLC) coating (photo) ejectors with an antitwist lock and many others All of these so-called standardized specials come in a wide range of stocked dimensions

The Rainer Knarr Group operates its own mould making division There-fore it well understands the needs and challenges of mould makers and

injection moulders The supplier sup-ports customers by offering a flexible ordering and deliv-ery servicemdashwith same-day shipping even for emergency orders received on Saturdaymdashan on-line shop and CAD data that is available for downloading

Always working on developing better solutions Rainer Knarr has recently launched several new product lines One is the huge XXL programme of flat ejector pins This line features pins in dimensions other than the well-known standard ones In addition it includes flat ejec-tors with corner radii and a DLC coat-ing flat ejectors with a long sheet and high-speed flat ejectors

Another line con-sists of patented hardened or nitrid-ed stepless ejector sleeves designed to facilitate reduction of the guide length

Also new from Rainer Knarr is a range of waved deflection baffles made of plastic which help ensure efficient balanced

mould cooling And the last highlight-ed recent introduction from the com-pany is a series of ejectors for outline pins that are made of hot-working steel hardened to 53 HRc for opti-mum machinability

Service-Oriented Supplier Provides Standard Mould Parts and Standardized Specials

raquo Rainer Knarr Vertriebs GmbHHelmbrechts Germanywwwrainer-knarrde

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

wwwthebrightworldofmetalscom wwwgmtnde

One date ndash one place ndash four eventsMake the most of four high-calibre trade fairs ndash for foundry technology metallurgy thermo process technology and precision castings ndash in one place and with one entrance ticket

The industriesrsquo Number 1 worldwide multiple synergies connections and networks all in just one show visit Welcome to Duumlsseldorf

The Bright Worldof MetalsDuumlsseldorf Germany 28 June ndash 02 July 2011

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Interview

heat treatment to all grades of steel That is the best prerequisite for warp-free machining of parts

What do you consider to be Meusburgerrsquos most important product rangeManufacturing plates for injection moulding and punching tools clearly is our biggest strength in rela-tion to our competitors Meusburger uses the best raw materials and suppliers and we implement a programme of complete quality assurance through-out the production process

How important is research and development to Meus-burger Standard MouldsWe place great value on products that provide a clear added value for our customers Therefore we develop new products by working together with customers to fulfill not only their specific needs but also and especially the needs of the market generally

Is Meusburger GmbH active in AsiaIn 2010 we opened a new sales office in Wuxi China in Jiangsu Province The reason for that is that many of our customers have manufacturing operations in China and have expressed an inter-est in using standard products made by Meusburger there As a supplier of high-quality standard parts we naturally thought it was important for us to have an in-country sales office of our own

Incidentally from May 17 to May 20 this year Meusburger GmbH will be represented for the first time at the Chinaplas trade fair which is being held in the city of Guangzhou China We invite read-ers intending to visit that show to come see us at Stand D 41 in Hall 32

raquo Meusburger Georg GmbH amp Co KGWolfurt Austriawwwmeusburgercom

The investment of millions of euros in the Meusburger production facility in Wolfurt in recent years extended the companyrsquos capabilities For example new furnaces allow the standard parts manufacturer to produce stress-relieved components in greater volume

18

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Advanced series of customized hot runner systems a thoroughly innovative new solution

from DME has been designed to free mould makers from the limita-tions imposed by ldquohalf-

standardrdquo solutionsmdashthat is the use of standard

products to construct a special hot runner system

With the concept-products of the Advanced series the

moulder receives a fully cus-tomer-specific system tailored

to defined needs without any compromising that will perform

exactly as it should

This hot runner series was made possible by the development of sev-eral different nozzle tips with new openings These provide an opti-mal solution for every material and accommodate lateral-injection and multiple-gating requirements Within 24 hours of request DME will offer a quotation for a complex hot runner solution including a 3D drawing and a multiflow system if needed Deliv-ery of such a system can be expect-ed in 7 to 20 working days depend-ing on the complexity plus transport Expedited delivery also is available

raquo DME EuropeMechelen Belgiumwwwdmeeucom

Custom Hot Runners without Compromise Are Available via New System Solution

Rainer Knarr Vertriebs GmbH spe-cializes in the manufacture and sup-ply of standard and custom mould parts The company prides itself on including in its standards line mould accessories that other suppliers might offer only as specials

Beyond its extensive range of stan-dard components Rainer Knarr also provides custom mould components for tool and mould makers and injec-tion-moulders such as flat ejector pins with corner radius flat ejector pins with an extralong blade step-less sleeve ejectors pins that have a diamondlike-carbon (DLC) coating (photo) ejectors with an antitwist lock and many others All of these so-called standardized specials come in a wide range of stocked dimensions

The Rainer Knarr Group operates its own mould making division There-fore it well understands the needs and challenges of mould makers and

injection moulders The supplier sup-ports customers by offering a flexible ordering and deliv-ery servicemdashwith same-day shipping even for emergency orders received on Saturdaymdashan on-line shop and CAD data that is available for downloading

Always working on developing better solutions Rainer Knarr has recently launched several new product lines One is the huge XXL programme of flat ejector pins This line features pins in dimensions other than the well-known standard ones In addition it includes flat ejec-tors with corner radii and a DLC coat-ing flat ejectors with a long sheet and high-speed flat ejectors

Another line con-sists of patented hardened or nitrid-ed stepless ejector sleeves designed to facilitate reduction of the guide length

Also new from Rainer Knarr is a range of waved deflection baffles made of plastic which help ensure efficient balanced

mould cooling And the last highlight-ed recent introduction from the com-pany is a series of ejectors for outline pins that are made of hot-working steel hardened to 53 HRc for opti-mum machinability

Service-Oriented Supplier Provides Standard Mould Parts and Standardized Specials

raquo Rainer Knarr Vertriebs GmbHHelmbrechts Germanywwwrainer-knarrde

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

18

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Advanced series of customized hot runner systems a thoroughly innovative new solution

from DME has been designed to free mould makers from the limita-tions imposed by ldquohalf-

standardrdquo solutionsmdashthat is the use of standard

products to construct a special hot runner system

With the concept-products of the Advanced series the

moulder receives a fully cus-tomer-specific system tailored

to defined needs without any compromising that will perform

exactly as it should

This hot runner series was made possible by the development of sev-eral different nozzle tips with new openings These provide an opti-mal solution for every material and accommodate lateral-injection and multiple-gating requirements Within 24 hours of request DME will offer a quotation for a complex hot runner solution including a 3D drawing and a multiflow system if needed Deliv-ery of such a system can be expect-ed in 7 to 20 working days depend-ing on the complexity plus transport Expedited delivery also is available

raquo DME EuropeMechelen Belgiumwwwdmeeucom

Custom Hot Runners without Compromise Are Available via New System Solution

Rainer Knarr Vertriebs GmbH spe-cializes in the manufacture and sup-ply of standard and custom mould parts The company prides itself on including in its standards line mould accessories that other suppliers might offer only as specials

Beyond its extensive range of stan-dard components Rainer Knarr also provides custom mould components for tool and mould makers and injec-tion-moulders such as flat ejector pins with corner radius flat ejector pins with an extralong blade step-less sleeve ejectors pins that have a diamondlike-carbon (DLC) coating (photo) ejectors with an antitwist lock and many others All of these so-called standardized specials come in a wide range of stocked dimensions

The Rainer Knarr Group operates its own mould making division There-fore it well understands the needs and challenges of mould makers and

injection moulders The supplier sup-ports customers by offering a flexible ordering and deliv-ery servicemdashwith same-day shipping even for emergency orders received on Saturdaymdashan on-line shop and CAD data that is available for downloading

Always working on developing better solutions Rainer Knarr has recently launched several new product lines One is the huge XXL programme of flat ejector pins This line features pins in dimensions other than the well-known standard ones In addition it includes flat ejec-tors with corner radii and a DLC coat-ing flat ejectors with a long sheet and high-speed flat ejectors

Another line con-sists of patented hardened or nitrid-ed stepless ejector sleeves designed to facilitate reduction of the guide length

Also new from Rainer Knarr is a range of waved deflection baffles made of plastic which help ensure efficient balanced

mould cooling And the last highlight-ed recent introduction from the com-pany is a series of ejectors for outline pins that are made of hot-working steel hardened to 53 HRc for opti-mum machinability

Service-Oriented Supplier Provides Standard Mould Parts and Standardized Specials

raquo Rainer Knarr Vertriebs GmbHHelmbrechts Germanywwwrainer-knarrde

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

Cover Story | Product Focus

raquo Synventive Molding Solutions GmbH

Bensheim Germanywwwsynventivecom

HIGH PRECISION MOLDS

VALVE GATE SYSTEMS

MICRO MOLDING SYSTEMS

ENGINEERING amp CONSULTING

wwwmaenner-groupcom

maumlnner valve gate systems are equipped with maumlnnerlsquos patented Cylindrical Valve Gate for impeccable optical gate quality

The systems are specifi cally designed for large-volume production with short cycle times and for processing resins with narrow processing windows

Copied by many maumlnnerlsquos valve gate system is the original that lives up to its promise

The Original

Valve Gate Components Simplify Installation of Hot Runner System in Injection Mould

The hot runner product manufac-turer Synventive Molding Solutions has added two items to its line the Model 06E threadedscrew-fit hot runner nozzle and Model PNC3008 pneumatic bolt-on actuator for valve gate hot runner systems with Plugrsquon Playreg functionality

The Model 06E nozzle represents an enhancement of Synventiversquos offering of small threaded leakproof mani-fold nozzles It is supplied in thermal gate and valve gate options fea-tures a 6-mm flow bore (with 20-mm mould cutout) and is designed for small shot weights up to 100 g per nozzle Being threaded into the mani-fold the 06E nozzle provides a leak-proof system without critical stack-up dimensions to be maintained The nozzle comes in lengths of 60 to 200 mm It is externally heated by replaceable heaters with integrated replaceable thermocouples

When Model 06E nozzles are used as a valve gate system and combined with a Synventive bolt-on actuator the complete hot runner system is supplied prewired and preassembled and without any need for hoses the lines are drilled into the top clamp plate This configuration allows for simple Plugrsquon Play mould installation

The PNC3008 bolt-on valve gate actuator also simplifies hot runner installation in the mould by providing Plugrsquon Play capability Among the key features of the actuator is a custom-er-supplied cover plate that allows the valve pin to be removed or adjust-ed without necessitating removal of

the top clamp plate In turn the top clamp plate can be removed without

valve pins having to be removed from the hot runner No extra pneumatic or cooling hoses are required nor are side-forceload-on valve pins the pins are perfectly aligned Active cooling is provided through the back plate

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

20

Cover Story | Product Focus

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Shotscope NXreg injection moulding process and pro-duction monitoring soft-ware has been enhanced by its developer Husky Injec-tion Molding Systems for improved monitoring of ener-gy consumption throughout an injection moulding facility The integrated system intro-duced in 2009 helps manufac-turers characterize production out-put and processes statistically at the discrete-system and plantwide lev-els in order to optimize productivity while minimizing scrap and system downtime By providing real-time monitoring and analysis Shotscope NX enables users to simplify report-ing improve data flow and coordi-nate more-efficient plant scheduling

from light fixtures to specific chill-ers to complete injection moulding cells and determine the kilowatt-hours of energy used in producing a kilogram of plastic Being able to

get such data can result in more-effective energy management

New Shotscope NX features include an enhanced user inter-face and Web-based software that allows users to access information from an unlimit-

ed number of collection points anywhere and at any time The

software is compatible with any brand of injection moulding equipment

raquo Husky Injection Molding Systems SA

Dudelange Luxembourgwwwhuskyca

Production Monitoring Software Optimizes Energy Use in Injection Moulding Processes

A cold runner system for the injec-tion of liquid-silicone resins is avail-able from Rabourdin the European manufacturer and supplier of metal mould components and hot runner

systems for ther-

moplastic injection moulding The cold block built into the upper part of the mould includes the resin distri-bution runners and the nozzles feed-ing each cavity The whole unit is reg-ulated by appropriate water circuits

In order to optimize production quality and liquid flow for

each cavity the nozzles can be open or closed with a sealing needle

activated by a pneumat-ic cylinder and the feed-

ing runners are equipped with flow limiters that can

be adjusted from outside the mould The two parts of the mould can be assembled via

an outside flanging systemRabourdin is now develop-

ing an electromechanically con-trolled version of this product for

moulds intended for use in white rooms Its cold blocks can be used to build multicavity mould tooling

Rabourdin works with mould mak-ers in developing and adjusting their silicone moulds providing a com-plete service from analysis of the part to construction of the mould By offering standardized solutions that embody tried and tested technical systems the company enables cus-tomers to realize significant advan-tages in productivity and mainte-nance without incurring burdensome investment costs Its capabilities extend to satisfying complex require-ments in silicone and thermoplastic multimaterial moulding

Adjustable Cold Runner System Ensures Good Injection and Flow of Liquid Silicone

raquo Rabourdin GroupeMarne-la-Valleacutee Francewwwrabourdinfr

The latest enhancements to the software provide fine statistical detail regarding energy use through the entire moulding facility rather than at just one machine Husky custom-ers can now monitor all sources of energy consumption individually

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

raquo Hasco Hasenclever GmbH + Co KGLuumldenscheid Germanywwwhascocom

With its development of the Multi Shot Z10440 hot runner nozzle for the injection-moulding of products via side or edge gating Hasco Hasen-clever GmbH amp Co KG succeeded in combining the advantages of side gating with maintenance-friendly assem-bly and precise tip positioning The innovation enables manufacturers to produce high-precision plastic arti-cles with simply designed moulds Also they can shut down a cavity or replace a tip easily with the mould on the machine thereby maintaining high production reliability

Compensation for thermal expan-sion along the nozzle during heat-ing is effected by means of a special device in the nozzle head that keeps the nozzle tip positioned centrally in the gate regardless of processing and mould temperatures This allows pre-cise filling of as many as six cavities with one nozzle

The Multi Shot Z10440 grew out of a need to eliminate remaining disadvantages from existing nozzle technology for side-gate-moulding caps and closures Hasco worked with a manufacturer to develop a way to define the position of nozzle

Maintenance-Friendly High-Precision Technology for Efficient Side-Gate Moulding

tips making tip behaviour more pre-dictable by ensuring that tip posi-tion (in the centre of the gate) was unaffected by temperature differ-ences between mould and nozzle The result was the Z10440 avail-able with two four or six nozzle tips all of which are individually replace-able and accommodating undivided mould inserts

Because the nozzle tip and seal-ing ring are together in one segment of the hot runner construction (inset photo) they can easily be assembled or dismantled The patented fixing mechanism allows maintenance to be carried out from the parting line

Cover Story | Product Focus

Mastip the global supplier of hot runner systems provides

technical solutions for demanding engineering resins

Proudly supported in Europe byMastip HRS

Strack Norma GmbH Tekis Teknik AS

Hales Tool amp Die Ltd Sverital SpA

your partner in technical mouldingsolutions

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

22

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16ACB International Helmond Netherlands +31 492 544433 1 3 7 10 12ACIM Jouanin Evreux France +33 232 623420Agathon Ltd Solothurn Switzerland +41 32 6174502 1 3 12AMPCO Metal SA Marly Switzerland +41 26 4399300 7Amtek Precision Engineers Ltd Totnes Devon UK +44 1803 865665 4 12Apfel Metallverarbeitung GmbH Dossenheim Germany +49 6221 87610 14AW Precision Ltd Rugby Warks UK +44 1788 542271 1Berger Tools Ltd Sevenoaks Kent UK +44 1732 763377 1 2 12 13 14Braunform GmbH Bahlingen Germany +49 7663 9320133 2 4 6 9 11 15Cavaform International LLC St Petersburg FL USA +1 727 384-3676 4 7 9Cirtes Saint-Dieacute-des-Vosges France +33 329 551171 6CodiproLux Wiltz Luxembourg +352 2681541 13 14Cumsa Sant JustBarcelona Spain +34 93 4732552 29 6 9 10 11Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844Deutsche Edelstahlwerke GmbH Witten Germany +49 2302 290 13 2 4 6Dimension Eden Prairie MN USA +1 952 906-2258Dimitris Kyriazis Athens Greece +30 210 3454876 13DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16DMS Diemould Service Co Ltd High Wycombe Bucks UK +44 1494 523811 1 2 3 5 7 8 9 10 11 12 13 14Drei-S-Werk Schwabach Germany +49 9122 15050 7 12ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 3 7 12EAS Europe BV Renswoude Netherlands +31 318 477010 5Eberhard Werkzeugtechnologie Nordheim Germany +49 7133 1000 3 7 9 12 14EDM-Tec oHG Bruttig-Fankel Germany +49 2671 915150 10 11 13 14Eldracher SL Badalona Spain +34 93 2842054 1 7 12Euracon Rotterdam Netherlands +31 10 7142633 3 5 13 14 16Exaflow GmbH amp Co KG Gross-Umstadt Germany +49 6078 78910FCPK Bytow Sp zoo Kielce Poland +48 59 8229700 2 3 5 8 9 10 11 12 13Fine Cut Graphic Imaging Ltd Lancing W Sussex UK +44 1903 751666 1 2 3 4 7 8 9 10 11 12 14Fluid Conditioning Systems Ltd Warwick UK +44 1926 623170 6Fodesco Oy Lehmo Finland +358 40 303101 1 2 3 5 7 10 12 15Frintec GmbH Werneck Germany +49 9722 944036 1 6 10 11Hales Tool amp Die Ltd Maldon Essex UK +44 800 6348800 1 2 3 4 5 6 7 8 9 10 11 12 13 15Hardinge Super Precision Europe GmbH Krefeld Germany +49 2151 496490 3Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 2 3 5 6 7 8 9 10 11 12 13 14 15Helix ToolsArti Takim Bursa Turkey +90 224 4110020 5Hommer Tool amp Mfg Inc Arlington Heights IL USA +1 847 394-3355 3 4 7 9 12Hon Hamn Group Corp Taipei Taiwan +886 2 29956783 10 11 12 13Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020HP Systems SA Ennery France +33 1 34353838

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

wwwdmeeucomwwwdmeeucom

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

23wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE18 21 22 23 24 25 28 32 wwwacbtoolsnl

19 wwwacim-jouaninfr18 23 34 wwwagathonch18 41 wwwampcometalcom

wwwamtek-precisioncomwwwapfel-gmbhde

34 41 wwwawprecisioncom18 20 21 22 23 24 31 34 41 wwwberger-toolscouk

40 wwwbraunformcom32 wwwcavaformcom

29 wwwcirtesfrwwwcodipronet

22 32 wwwcumsacom19 wwwdaltonelectriccom

wwwdew-stahlcom17 18 40 wwwdimensionprintingcom

27 31 34 wwwkyriazisgr17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 wwwdmeeucom

18 19 21 23 24 26 27 28 31 32 33 35 36 37 38 41 wwwdms-diemouldcoukwwwdrei-s-werkcom

23 35 36 wwwensintcom30 wwweaschangesystemscom

18 wwweberhardde17 18 19 25 33 34 37 38 41 wwwedm-tecde

18 21 23 24 31 35 wwweldrachersles17 18 19 20 27 34 wwweuraconnet17 32 39 40 wwwexaflowde

18 20 23 24 25 31 32 33 34 35 36 37 39 40 41 wwwfcpkpl18 24 26 27 28 30 31 34 36 wwwfcadvancedengineeringcouk

19 wwwfluidcscom18 21 22 23 24 25 31 32 34 35 36 37 wwwfodescofi

19 20 25 39 wwwfrintecde17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 wwwhalesmastipcouk

wwwhardingecom17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 37 38 39 40 41 42 wwwhascocom17 26 30 40 wwwartitakimcom17 40 wwwhommercom

19 20 27 31 32 34 37 41 wwwhonhamncomtw19 wwwhotsetde

20 wwwhp-systemsfr

Gear

s

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

Renewed Hot Runner portfolio Essential amp Advanced Series

From standard to complex hot runner solutions

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

24

Cover Story | Quick Sourcing Grid

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

See

Ad o

n Pa

geAl

ignm

ent C

ompo

nent

s

Base

sBu

shin

gsCa

vitie

sCo

nnec

tors

Cou

plin

gs

Cool

ing

Syst

ems

Core

Pin

sCo

re P

ulls

Core

sD

ate

Stam

psM

arki

ng S

yste

ms

Ejec

tion

Syst

ems

Ejec

tor P

ins

Slee

ves

Plat

es

Fast

ener

sFi

xtur

esFr

ame

Inse

rt S

yste

ms

Gask

ets

Tool amp MouldComponents

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16HSB Normalien GmbH Schwaigern Germany +49 7138 8127490 1 3 4 5 10 11 12HTV Ic ve Dis Ticaret Ltd Sti Niluumlfer-Bursa Turkey +90 224 4527479i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 10Intercom Srl Gorgonzola (MI) Italy +39 02 95300202 1 2 3 6 7 12Kantemir Auray France +33 297 566521 2Kern Normalije Izola Slovenia +386 5 6165000 1 2 3 5 6 7 9 10 11 12 13 14Keronite International Ltd Cambridge UK +44 1223 893222Kiefer Werkzeugbau GmbH Schwaigern Germany +49 7138 97320 1 3 4 5 10 11 12Meusburger Georg GmbH amp Co KG Wolfurt Austria +43 5574 67060 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Millutensil Srl Milan Italy +39 02 29404390 3 13Misumi UK Ltd Staines Middx UK +44 1784 465530 2 3 6 7 8 9 10 11 12 13 14 15 16Moldes Barcelona SA Polinya Spain +34 93 7132162MTS Sensor Technologie GmbH amp Co KG Luumldenscheid Germany +49 2351 95870Nonnenmann GmbH Winterbach Germany +49 7181 40870 3 5 6 7 12 13Nuova Ret Srl Cinisello Balsamo (MI) Italy +39 02 66049481 3 7 10 12OCS Srl Adrara SM (BG) Italy +39 035 933487 4 16Opitz GmbH Aschaffenburg Germany +49 6021 80088 10Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400Pedrotti Normalizzati Italia SpA Gavardo (BS) Italy +39 036 5330111 2 3 6 10 11 12Plasel Irrigation Molds Lavon Israel +972 4 9089840 4 9 15Praumlzi-Flachstahl AG Everswinkel Germany +49 2582 7601Progressive Components Europe Ltd Oldham Manchester UK +44 161 6696191 1 3 4 5 7 9 10 11 12 15Quiri Hydromecanique Duttlenheim France +33 388 048418RampD Leverage Sutton-in-Ashfield Notts UK +44 1623 556287 7 9Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 2 3 5 7 10 12 13Roehr Tool Corp Hudson MA USA +1 978 562-4488 9RUD Ketten Rieger amp Dietz GmbH u Co KG Aalen Germany +49 7361 5040 13Saglam Metal AS Istanbul Turkey +90 212 6712331 3 12Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Schoumlttli AG Mould Technology Diessenhofen Switzerland +41 52 6462222 4Sideco SpA Grumolo delle Abbadesse (VI) Italy +39 0444 263838 2 3 12Staumlubli Faverges France +33 450 656060 5Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 2 3 5 6 7 8 9 10 11 12 13 14 15Syndal SpA Trezzano sul Naviglio (MI) Italy +39 02 4842051 2 3 7 12Taizhou Huangyan Mingsheng Mould Co Ltd Taizhou China +86 576 84023808Tecnomagnete SpA Lainate (MI) Italy +39 02 937591Thermacore Europe Ltd Ashington Northd UK +44 1670 859500 6 16Vega Srl Castellanza (VA) Italy +39 0331 481077Watlow GmbH Kronau Germany +49 7253 94000Wika Instruments Ltd Oakville ON Canada +1 905 337-1611

slides

undercuts

ejection

cooling

traceability

accessories

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

25wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing GridGe

ars

Sprin

gs

Sock

ets

Guid

es

Stop

Pin

sSl

eeve

s

Hea

ting

Equi

pmen

t

Supp

ort P

illar

s

Hyd

raul

ic C

ylin

ders

Tape

r Loc

ks

Inte

rlock

s

Ther

mal

Pin

sH

eat P

ipes

Latc

h Lo

cks

Tunn

el G

ates

Lead

er P

ins

Unsc

rew

ing

Mec

hani

sms

Loca

ting

Ring

s

Wea

r Pla

tes

Mou

ld In

sula

tion

Wiri

ng

Mou

ld P

ort P

lugs

Sea

ls

O-R

ings

Part

ing-

Line

Slid

e Lo

cks

Pres

sure

Con

trols

Sens

ors

Mon

itors

Switc

hes

Qui

ck M

ould

-Cha

nge

Syst

ems

Scre

ws

Slid

esS

lide

Lock

s

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WEBSITE23 25 27 31 33 34 wwwhsb-normaliende

34 wwwhtvcomtr39 wwwi-moldcom

17 18 35 41 wwwintercomonlineitwwwkantemircom

18 20 23 24 25 31 32 33 34 35 36 37 39 41 wwwkernsi25 wwwkeronitecom

23 25 27 31 33 34 wwwkiefer-moldde18 21 22 23 24 25 26 27 28 30 31 32 34 35 36 37 39 41 wwwmeusburgercom18 20 25 26 29 wwwmillutensilcom

17 18 19 20 23 24 25 27 29 31 32 33 34 35 36 37 41 42 wwwmisumi-europecom30 wwwmoldesbarcelonacom

29 wwwmtssensorde18 21 23 24 27 31 32 33 34 35 36 37 wwwnonnenmann-gmbhde18 21 24 31 34 35 wwwnuovaretit

27 wwwocs-stampiitwwwopitz-gmbhde

25 39 wwworyconcom18 19 23 25 26 27 31 33 34 36 wwwpedrottiit

25 wwwplaselcom41 wwwpraezide

21 22 23 28 32 34 35 36 37 wwwprocompscom20 wwwquiricom

30 41 wwwrdtoolcouk18 19 24 27 31 32 34 36 38 41 wwwrabourdinfr

wwwroehrtoolcom30 31 wwwrudcom

17 23 31 wwwsaglammetalcom42 wwwsawich

wwwschoettlicom18 25 31 34 wwwsideco-spait

wwwstaublicom18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 wwwstrackde18 23 34 35 36 41 wwwsyndalit

25 26 30 wwwtsmpcn30 wwwtecnomagnetecom

27 38 wwwthermacore-europecom20 40 wwwvegacylindercom

19 wwwwatlowde19 29 wwwwikaca

we have been providing standardized solutions to

moulders and mould makers for 20 years helping to

improve productivity and minimize costs and

everyday problems

contact us and discover

a world of solutions

juan ramoacuten jimeacutenez 8 08960 - sant just desvern - barcelona - spain Tel +34 93 473 25 52 - Fax +34 93 473 49 19 infocumsacom wwwcumsacom

CUMSAINNOVATIVE STANDARD PARTS FOR MOULDS

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

26 European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Cover Story | Quick Sourcing Grid

COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11Asso Srl Florence Italy +39 055 316053 1 3 4 6 7 9 10 11Braunform GmbH Bahlingen Germany +49 7663 9320133 2 3Dalton Electric Heating Co Inc Ipswich MA USA +1 978 356-9844 1DME Europe Mechelen Belgium +32 15 215079 22 1 2 3 4 6 7 9 10 11ENS International Srl Villanuova sul Clisi (BS) Italy +39 0365 373367 7Ewikon Heiszligkanalsysteme GmbH Frankenberg Germany +49 6451 5010 2 3 4 6 7 9 10 11Fast Heat Ltd Eastbourne E Sussex UK +44 1323 647375 1 2 3 4 6 7 9 10 11Frintec GmbH Werneck Germany +49 9722 944036 2 3 4 6 7Gammaflux Europe GmbH Wiesbaden Germany +49 611 973430Guumlnther Heisskanaltechnik GmbH FrankenbergEder Germany +49 6451 50080 1 2 3 4 5 6 7 9 10Hasco Hasenclever GmbH + Co KG Luumldenscheid Germany +49 2351 9570 15 1 2 3 4 5 6 7 8 9 10 11Heitec Heisskanaltechnik GmbH Burgwald-Bottendorf Germany +49 6451 72830 27 2 3 4 5 6 7 9 10 11Hotset Heizpatronen und Zubehoumlr GmbH Luumldenscheid Germany +49 2351 43020 1Husky Injection Molding Systems Ltd Bolton ON Canada +1 905 951-5000 1 2 3 4 5 6 7 8 9 10 11Husky Injection Molding Systems SA Dudelange Luxembourg +352 52 1151 2 3 4 6 10i-mold GmbH amp Co KG Michelstadt Germany +49 6061 965640 2 3 4 6 7 10Incoe International Europe Roumldermark Germany +49 6074 89070 1 2 4 6 7 9 10 11INglassHRSFlow San Polo di Piave (TV) Italy +39 0422 750111 2 3 4 6 7 9Ivaldi Evreux France +33 232 382616 1Kantemir Auray France +33 297 566521 4Maumlnner Solutions for Plastics Bahlingen Germany +49 7663 6090 19 2 3 4 6 7 9MasterFlow AB Vaumlstervik Sweden +46 490 82260 1 2 3 4 5 6 7 9 10 11Mastip Technology Ltd Auckland New Zealand +64 9 9702100 21 2 3 4 6 7 8 9 10 11MHT Mold amp Hotrunner Technology AG HochheimMain Germany +49 6146 9060 3 6Mold Hotrunner Solutions Inc Georgetown ON Canada +1 905 873-1954 2 3 4 5 6 7 9 10Mold-Masters Europa GmbH Baden-Baden Germany +49 7221 50990 1 2 3 4 5 6 7 9 10 11Orycon Control Technology Inc Ocean NJ USA +1 732 922-2400 1 2 3 4 5 6 7 8 9 10 11PSG Plastic Service GmbH Mannheim Germany +49 621 71620 1 3 4 6 11Rabourdin Groupe Marne-la-Valleacutee France +33 1 64764101 47 3 4 6 7Runipsys Europe SAS Mery France +33 479 343770 6Runner-Plast Pringy France +33 450 528121 3 4 6SISE Oyonnax France +33 474 773453Sawi Mess- und Regeltechnik AG Winterthur Switzerland +41 52 3205050Strack Norma GmbH amp Co KG Luumldenscheid Germany +49 2351 87010 10 1 2 3 4 5 6 7 8 9 10 11Synventive Molding Solutions GmbH Bensheim Germany +49 6251 93320 2 3 6 7Thermodyne SIPA Div Vittorio Veneto (TV) Italy +39 0438 911739 2 3 4 6Thermoplay SpA Pont Saint Martin (AO) Italy +39 0125 800311 43 2 4 6 9 10Tuumlrk + Hillinger GmbH Tuttlingen Germany +49 7461 70140 5 1Watlow GmbH Kronau Germany +49 7253 94000 1Witosa GmbH Frankenberg Germany +49 6451 2309870 2 3 4 6 7 9 10

See

Ad o

n Pa

geH

eatin

g El

emen

ts

Hot

Hal

ves

Fully

Wire

d

Hot

Run

ner C

ompo

nent

s

Hot

Run

ner M

anifo

lds

Hot

Run

ner P

ort P

lugs

Sea

ls

Hot

Run

ner S

yste

ms

Hot

Spr

ue B

ushi

ngs

Mel

t-Man

agem

ent P

rodu

cts

Noz

zles

with

Bus

hing

s

Noz

zles

Edg

e Ga

te

Noz

zles

Filt

er

Hot Runner Systems amp Components

Mastip is a leading designer and manufacturer of innovative hot runnerworldwide Our comprehensive product range includes complete Hot

in thermal and valve gate configurations to satisfy the most

your partner in technical mould

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Cover Story | Quick Sourcing Grid

12 13 14 15 16 17 18 19 20 21 22 23 WEBSITE12 13 14 15 16 17 18 19 20 21 22 23 wwwassoit

13 15 wwwbraunformcomwwwdaltonelectriccom

12 16 19 20 22 23 wwwdmeeucomwwwensintcom

12 13 15 16 17 19 20 22 wwwewikoncom12 13 14 15 16 17 19 20 21 22 wwwfastheatukcom12 13 17 19 wwwfrintecde

20 wwwgammafluxde12 13 16 17 18 19 20 21 22 wwwguenther-hotrunnercom12 13 14 15 16 17 18 19 20 21 wwwhascocom12 13 14 15 16 17 18 20 wwwheiteccom

wwwhotsetde12 13 14 15 17 18 19 20 21 22 23 wwwhotrunnerscom12 17 19 20 wwwhuskyca12 16 17 20 wwwi-moldcom12 13 14 16 17 19 20 22 23 wwwincoede12 13 14 15 17 19 20 22 23 wwwinglassit

wwwivaldifrwwwkantemircom

17 19 20 wwwmaenner-groupcom12 13 14 15 16 18 19 20 21 22 23 wwwmasterflowse12 13 15 16 17 18 19 20 21 wwwmastipcom

19 20 22 wwwmht-agde12 16 17 19 20 22 23 wwwmoldhotrunnersolutionscom12 13 15 16 17 19 20 21 22 23 wwwmoldmasterscom12 13 15 16 17 18 19 20 21 22 23 wwworyconcom

13 14 17 20 wwwpsg-onlinede16 19 20 22 wwwrabourdinfr

19 wwwrunipsyscom17 wwwrunner-plastcom

20 22 23 wwwsisefr20 wwwsawich

12 13 14 15 16 17 18 19 20 21 22 23 wwwstrackde12 17 20 wwwsynventivecom

14 19 wwwsipait13 17 19 20 23 wwwthermoplaycom

wwwtuerk-hillingerde20 wwwwatlowde

12 16 17 18 20 wwwwitosade

Noz

zles

Hot

Tip

Noz

zles

Hyd

raul

ic V

alve

Gat

e

Noz

zles

Mac

hine

Noz

zles

Mec

hani

cal V

alve

Gat

e

Noz

zles

Mul

titip

Tem

pera

ture

Con

trol

s

Noz

zles

Pne

umat

ic V

alve

Gat

e

Tip

Hea

ter P

rodu

cts

Runn

er-B

alan

cing

Pro

duct

s

Valv

e Ga

te C

ontr

olle

rs

Stac

k M

ould

Hot

Run

ners

Valv

e Ga

te S

eque

ncer

s

ing solutionssolutions to the plastics industryHalf or manifold only solutionsdemanding applications

1313

131313

1313

13

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

28

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Hauzer Techno Coating BVVenlo Netherlandswwwhauzertechnocoatingcom

DLC coatings are common in automotive applications because of their excellent tribological prop-erties Their coefficient of friction is low and they display nonstick-ing behaviour Depending on how the coating is deposited (sput-tering plasma-assisted chemical vapour deposition or arc evapora-tion) properties can be adapted to the purpose DLC is suitable for coating drills inserts end mills saw blades taps punches plas-tics moulds and dies Applications for DLC-coated tools include the machining of aluminium other nonferrous metals and plastics

Another example of technolo-gy transferred from one market to another is hydrogen-free DLC or ta-C During the European Nano-coat project in which Hauzer took part tests were performed on sev-eral DLC coatings used on auto-

motive engine components at the Fiat Research Centre in Turin The

researchers concluded that ta-C coatings were unsur-passed in their combination of high hardness and low friction coefficient Hauzer applied knowledge gained from this project to solve adhesion issues involving ta-C The result is a range of ta-C coatings that have good adhesion and hardness val-ues (40ndash70 GPa and DB 1ndash2) and can be used industrially Hauzer has coated end mills with ta-C (Figure 1)

Measurements of impact effect taken by an engine man-ufacturer showed that the ta-C coating was still intact following an impact load of 2 kN only small cracks were visible Such an impact load had previously removed a benchmark coating A Rockwell indent reveals the ta-C coatingrsquos good adhesion (Figure 2)

Hydrogen-free ta-C coatings are produced by means of arc technology (circular arc or laser arc) and possess a diamond-like structure They can achieve a typi-cal hardness between 3000 and 7000 HV Their typical coefficient of friction falls between 002 and 01 The advantageous features of ta-C taken together with Hauzerrsquos solution of the adhesion issues make this coating promising for the future of precision tooling

In the development of physical-vapour-deposition (PVD) coat-

ings market cross-fertilization has been important For example the forming- and cutting-tool market can take advantage of coat-ings developed for use on automotive engine compo-nents The Dutch PVD coat-ing expert Hauzer Techno Coating BV has transferred its diamond-like-carbon (DLC) tribological coating technology to the tool mar-ket with excellent results

Coating hardness and adhesion are key in many tool applications but other features of coatings also can be hugely advantageous Non-sticking performance for instance is essential in the machining of soft materials such as aluminium and plastics enhancing both tool life and productivity Smoothness on another hand is very desir-able in forming tools This prop-erty can eliminate the need for a posttreatment processing step All of these coating characteristics have been studied in automotive coating applications and coatings have been optimized

Hydrogen-Free DLC Coatings Make Tools Hard and SmoothA PVD coating technology with high potential in toolmaking is transferred from the automotive field

Figure 1

Figure 2

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

DO YOU WANT TO REDUCE YOUR MOLD DIMENSIONS

Use the double ejectionNEW

INNOVATIVE SOLUTIONS FOR MOLDS

Check wwwcumsacom for your official dealer

Eje

ctio

n s

olu

tio

ns

Key features

- Also works as the ejector guide pins and bushes having the possibilty of eliminating the need to install extra items

- Thanks to the assembly of the units away from the centre of mold but within the ejector frame the space required for

installation is drastically reduced leaving more space for other mechanisms

- The rear plates stops and the upper plates continues for the full ejection stroke

Mold closed

1st Stroke Both ejector plates

advance

2nd Stroke Only upper ejector

plates advance

DX Superior Double Ejection

More information at Internet

under Products News

wwwcumsacom

with integrated ejection plate guiding

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

30

Technology

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

raquo Guumlhring oHGAlbstadt-Ebingen Germanywwwguehringde

New Geometries Make Revised Drilling System More EfficientOptimized wear-resistant toolholders and interchangeable inserts with special cutting edges and application-specific surface finishes are also very adaptable

machines with heavy vibration stresses

Besides reducing wear the close hold-er diameter incre-ments of 05 mm improve guidance of the tool in the hole The higher system rigidity that results extends tool life and enhances workpiece surface finish

A tool shank that is reinforced to DIN

6535 HE ensures tight accurate clamping in the toolholder The satisfaction of the DIN standard for solid-carbide monobloc tools allows changeover to production with the Guumlhring system to take place at any time

The new inserts and holders of the revised HT 800 WP sys-tem are fully compatible with ear-lier system inserts and holders Thus the new inserts can be used with the previous holders and new holders will accept inserts of the preceding generation Drilling tests have shown that with either mixed combination the inclusion of new elements results in an effi-ciency improvement over the old HT 800 WP system

In addition to standard HT 800 WP tools Guumlhring supplies HT 800 WP stepped tools Also offered as a special solution are alternative insert coatings

Guumlhring oHG offers its HT 800 WP interchangeable-

insert drilling system with new geometries for inserts and holders thus providing new possibilities for efficient drilling in the hole diameter range between 11 and 2599 mm The system includes optimized holders for all regular drilling depths With respect to material geometry and surface finish the interchangeable inserts allow perfect adaptation to spe-cific applications in steel cast iron and aluminium Users will

see optimal machining results and enjoy economic efficiency

With their special microhoned cutting edges and application-spe-

cific surface finishes the interchangeable inserts of the HT 800 WP drilling system are particularly wear resistant The systemrsquos toolholders also are very wear resistant owing to their being made from an opti-mized material with nickel plating The availability of holders sized in increments of 05 mm adds to the

minimization of wear at the holder body

The holdersrsquo open-flute design ensures good chip evacuation even from deep holes Internal cool-ing supports the optimized flute cross section in this Coolant exiting through wide ducts in the flute provides plentiful cooling lubrication at the cutting edges and helps evacuate chips from the hole

The systemrsquos high-accuracy insert seat facili-tates problem-free manual insert change right in the machine Also inserts can be changed out more often before the holder needs to be replaced than is the case with conven-tional drilling systems because the holder mate-

rial resists wear at the seat Lock-able clamping screws ensure that the insert is retained securely in the holder even when used on

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

Exhibit with DEMAT worldwide

Trade Fair for Product Development Moldmaking and Tooling on 5 continentsldquoFrom Design to Prototyping to Series Productionrdquo

Nov 29 ndash Dec 02 2011 Frankfurt Main Germany

wwwdematcom

amerimold April 13 ndash 14 2011 Chicago USA

Rosmould June 15 ndash 17 2011 Moscow Russia

asiamold September 21 ndash 23 2011 Guangzhou China

afrimold September 27 ndash 29 2011 Johannesburg South Africa

Die amp Mould INDIA April 19 ndash 22 2012 Mumbai India

EuroMold BRASIL August 20 ndash 24 2012 Joinville SC Brazil

INTERMOLD to be announced Tokyo Japan

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

32

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Pfletschinger amp Gauch a Ger-man precision mould design

and construction company pro-duces multicavity and multiple-component moulds for medical and pharmaceutical technology companies among others The third-generation family company depends on SegoniFutur pro-duction planning software (PPS) from Segoni AG for its business organization and management

ldquoWe used to have several sys-tems running parallel to each otherrdquo explains the mould mak-errsquos managing director Michael Gauch ldquoThese included a self-made tool for precalculations and an industry solution for order management and final calcula-tions This setup wasnrsquot working owing to a lack of transparency and redundant data recording In particular comparing and analyz-

ing pre- and postcalcula-tions from the various systems was very time-consumingrdquo

ldquoThusrdquo Gauch says ldquoour goal was clearly to integrate our mould design and construction processes with one con-tinuous systemrdquo As the company envisioned it data entered once should be accessible to the sales administration and pro-duction departments and be able to serve as a basis for comparison and proj-ect calculations

After looking at vari-ous software solutions reports Pfletschinger amp Gauch technical direc-tor Roland Pfletschinger the company found itself identifying with Segonirsquos production philosophy ldquoWhat won us over was that unlike other PPS systems this solution was based on one con-cept for production orga-nizationrdquo he explains

Starting UpThe project got under way with a one-day workshop in which machine and staff hourly labour rates were determined Subse-quently the companyrsquos execu-tives talked about future trends in mould design and construction processes and discussed a vari-ety of process options in order to establish a uniform method of approach and process plan

The Segoni project manager at Pfletschinger amp Gauch Theodor Neumaier offers some insight into the process

ldquoWe use our rough cost calcula-tion when we get an inquiryrdquo he explains ldquoWe use the so-called fine calculation in which a work plan is created only when a customer actually places an order As soon as we have the final design it is the work-planning departmentrsquos task to plan and organize the project according to its parts list position This means that the mould design-er creates a component-specific work plan for every parts list posi-tion which will guide each mould component on its individual jour-ney through production and also serves for identification and docu-mentation Our system of shelves and boxes which was created at the company here in Plochingen creates additional transparencyrdquo

Basic training in the PPS soft-ware from Segoni lasted three days During the training cost calcula-tions bids and especially work plans for each component were created in SegoniPPMS and sent on to production

PPS Software Ups Production Transparency for Mould MakerImplementing SegoniFutur enables a company to achieve its organizational goal which was to integrate its mould design and construction processes

The new PPS software supports Pfletschinger amp Gauchrsquos storage system of boxes and shelves in keeping work plans in clear order

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

33

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Segoni AGBerlin Germanywwwsegonide

ldquoWith our old systemrdquo recalls Gauch ldquostarting at this point we introduced the shelf system and flooded production with work plans Basically we started with parallel systems On the one side we had sales doing bid estimates and on the other side we had the work-planning department creat-ing work plans for productionrdquo

Reaping BenefitsThese days Pfletschinger amp Gauch is better able to estimate each departmentrsquos workload and sched-uling and deadline management has become much more transpar-ent Moreover production as well as work planning has become more manageable reliable and clearly defined Material flow in production is greatly improved thanks to the work plans and shelf system The company thus gets fewer follow-up questions and

encounters fewer misunderstand-ings and other problems thereby lowering costs

The software improved trans-parency noticeably not only for the workers but also for manage-ment and company administra-tors The project management team now can use and learn from information gained from records of the length of time projects take

ldquoOur work plans include all of the information necessary for productionrdquo says Roland Pfletsch-inger ldquoWe decided to include the duration estimated by the work-planning department on the work plans in order to improve plan-ning reliabilityrdquo

Master Wolfgang Haible says he finds that the overview at a glance is a very useful tool This element of the software shows what tool components are located in which department and what work pro-cedures need to be performed at

which time In addition a tool-maker is able to access informa-tion about the status of mechani-cal production from a production terminal at any time

Transferring tasks between the two masters employed by Pfletsch-inger amp Gauch when one is on holiday for example is now much simpler Pfletschinger explains ldquoPreviously we would meet several days in advance and write lists Now we use the data to discuss two or three critical projects and the rest is already documentedrdquo

The companyrsquos two directors have concluded that even though a few kinks still need working out Pfletschinger amp Gauch is definitely on the right path and is benefiting every day from its decision to go with Segoni

The world of metalworking

INFOVDW ndash Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken eVCorneliusstrasse 4 60325 Frankfurt am Main GERMANYTel +49 69 756081-0 Fax +49 69 756081-74emovdwde middot wwwemo-hannoverde

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

34

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

More and more mould makers are relying on tryout press-

es to set their injection moulds perfectly Koller Formenbau und Kunststofftechnik GmbH in Ober-buumlrg Germany for example uses a Blue Line MIL 303 tryout press with a 3000-kN clamping force This machine was manufactured by Millutensil Srl and supplied by the Italian companyrsquos German agent Dremo Werkzeugmaschin-en GmbH (wwwdremo-wzmde)

Tryout presses donrsquot make anything but they are an essen-tial link in the production chain ldquoToday many OEM manufactur-ers explicitly require that mould suppliers wishing to bid against public tenders for bumper moulds should be equipped with least one 2 x 3-m spotting pressrdquo explains Max Koller CEO of Koller For-menbau und Kunststofftechnik ldquoNaturally a press is not an item that one can directly invoice but it is now often a prequalification requirementrdquo

High-precision mould machin-ing is incomplete without a tryout press these days To make his point clear Max Koller declares milling down to ldquozerordquo a dream ldquoPar-ticularly with very large moulds the last hundredths are obtained with a spotting pressrdquo he declares unequivocally Some companies use a crane to set half-moulds (ldquodetrimental to exact edgesrdquo warns Koller) and others try out the mould directly on the injec-tion press But in adopting such approaches says Koller ldquothey cannot work exactly or easilyrdquo

No CompromisesUsing a crane to try out a mould precludes simulation of injection forces And trying out the mould on the injection press requires accounting for the half-moulds and the force of gravity prevent-ing them from aligning parallel to

the machine Max Kollerrsquos think-ing is this ldquoThe outcome will never be good enough especially as the advancement of injection presses is typically a jerky motion Furthermore trying a mould out on an injection press is simply way too expensive And at last

Using a Powerful Yet Sensitive Tryout Press to Finish the JobTryout presses are an essential link in the production chain for mould builders One mould maker needing to try out large moulds found its ideal supplier

The mould punch rotates 180deg and is thereby set to the best operating positions by the press

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

35

Case Studies

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

raquo Millutensil SrlMilan Italywwwmillutensilcom

some parts must be pro-duced Anyone who ever tried to make adjustments to a hanging mould in a small room will know that this is far from ergonomicrdquo

So right from the outset Koller GmbH has not com-promised The fifth machine the company acquired was a spotting press and it was recently using several mod-els from various manufac-turers But when the mould maker needed to try out larger moulds than before it searched the market to find a new solution

Finding the Right PressThe height of Kollerrsquos indus-trial shed and cranes pre-sented a construction con-straint ldquoOur new press had to be very compact and installed on the ground to allow for ergonomic han-dling of the mouldsrdquo Max Koller explains ldquoWe wanted to develop a very efficient and user-friendly tryout processrdquo Thus the com-pany screened several manufac-turers in looking for an optimal solution

Kollerrsquos search ended at Mill-utensil The Blue Line MIL 303 had exactly the characteristics required Its four-cylinder control keeps the machine compact and minimizes overall height Further the pressing force is evenly dis-tributed over the entire surface of the table

A key reason for deciding in favour of purchasing the MIL 303 was the handling of moulds on the machine ldquoWe especially liked the fact that after the try-out the punch and counterpunch are automatically brought to a position where they can be eas-ily reworked or machined by the toolmakerrdquo reports Koller The

punch rotates up to 180deg and is then taken down from the press the counterpunch travels laterally from the press and can be rotated up to 70deg on each side

Says Koller ldquoThis makes both of them easy to access and ensures top visibility for the operator on all crucial areas in order to rapid-ly identify the ones where rework-ing is required and implement the needed measuresrdquo

Powerful Yet SensitiveThe Millutensil press can clamp powerfully but it is also very sensi-tive Four lasers situated alongside the press accurately control the parallelism ldquoThe machine is set to a tolerance range of 210 which is unique in the field of mould mak-ingrdquo notes Max Koller ldquoReaching that value alerts the control unit of a clear sign of failurerdquo

The machine has an intelligent

control system capable of detecting errors and safely driving the tool sections back ldquoThis ensures that the mould is not damaged even when a hammer is acciden-tally left thererdquo says Koller

Hydraulic connections enable the user to move the extractors of the mouldrsquos threading taps and slides on the press so that a complete cycle can be performed in one go Placement and hold-down force can be accurate-ly adjusted Optionally the press can be configured in such a way as to produce a first prototype with injected wax Koller GmbH does not use this feature however as its injection presses are efficient enough

lsquoAn Essential AidrsquoThe company does not use the Millutensil tryout press for new moulds only ldquoThe

machine is an essential aid for repairs and modification of used mouldsrdquo Max Koller explains ldquoas this task normally involves many different manual reworking phasesrdquo

Offering ergonomic worksta-tions and easy handling of mould components the press enables the companyrsquos employees to react quickly even when the neces-sary changes or repairs are com-plex These are often carried out overnight so that the mould can be used again the next day with minimal production downtime This flexibility and the capability to react quickly to OEM manu-facturersrsquo needs constitute impor-tant selling points for a mould manufacturer active in Germany as Koller can attest

ldquoZero millingrdquo is an illusion especially with large moulds A tryout press ensures accuracy to the last hundredths

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

36

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Forging Company Makes Dies from Tough Hard Tool SteelToolox 44 possesses properties that enable the manufacturer to produce high-quality prototypes and small series of die-forged parts quickly

Krenhof AG of Koumlflach Austria produces about

10 million die-forged parts annually Its customers are primarily in the automotive industry but also include manufacturers of commercial vehicles chain producers and companies in the formwork technology and mechanical engineering industries The company is operating in its meacutetier especially when it pro-duces complex parts in the medium-series range but it can offer quality and logistics capabilities befitting a higher-volume production level

Importantly Krenhof has been able to compete and grow thanks to continuous investment and the introduc-tion of innovations along the entire process chain Note-worthy is the fact that the company recently began to use Toolox 44 tool steel from SSAB for its forging dies

With its special properties Toolox 44 which has a hardness of approximately 45 HRc450 HB assumes a special position This steel offers an optimal compro-mise between hardness and toughness It provides good tem-perature toughness against the formation of fire cracks while at the same time being resistant to abrasion Toolox 44 is quite ame-nable to all standard separation and prestressing processes

SSAB gives the steel its high purity and outstanding tough-ness by formulating it with a low

raquo SSAB Oxeloumlsund ABOxeloumlsund Swedenwwwssaboxcom

carbon content As an additional benefit it delivers Toolox already hardened and tempered which saves the customer additional pro-cessing expenditure

ldquoWe use Toolox 44 tool steel for prototypes and small seriesrdquo says Matthias Hartmann Kren-hofrsquos managing director ldquoForma-tion of fire cracks is worst at the beginning of the forging while abrasion is nowhere near as com-mon here This allows us to refrain from using shielding without the customer experiencing any disad-vantages in terms of surface qual-ity or dimensional stabilityrdquo

Todayrsquos customers are demanding shorter delivery times for their forged prod-ucts Hartmann remarks But thatrsquos no problem As Hartmann explains ldquoTool-ox 44 has proven itself with demanding moulding tool geometries as wellrdquo This is important because ldquothe speed at which one can produce prototypes is often decisive when it comes to being hired as a series supplierrdquo

Krenhof AG uses state-of-the-art methods in construc-tion and toolmaking to ensure an efficient development process During the essential production steps of cutting forging and heat treatment high-quality machines and dedicated employees are able to hold tolerances for dimen-sions shape and joints very close for users this means that their own processes will

run better Rigorous production planning and the on-line collec-tion of operational data help to ensure that agreed-upon sched-ules are met And with Toolox 44 tool steel in its arsenal of advanced technologies Krenhof can produce small and pilot pro-duction series of forgings quickly

No one is surprised that the company has grown by an aver-age of better than 10 per year for the past 15 years

Krenhof can quickly and flexibly produce die-forged components in series of 1000 to 10000 parts This capability is supported by Toolox 44 tool steel which has proven itself with demanding moulding tool geometries

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

Itrsquos time to get Personal

Objet24 Personal 3D Printer

Visit us at PDM

18ndash19 May 2011 | Stand 54

RapidTech24ndash25 May 2011 | Stand 2-415

Price for Europe International pricing may vary Price excludes VAT options installation shipping local taxes and duties

+49 7229 77720infoobjetcomwwwobjetcom

Relevant Fortune 100 companies didnrsquot settle for second best

They invested in Objet 3D Printing technology

Objet24 From only 16900

Superior printing accuracy and low price

point for the creative freedom you deserve

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

38

Case Studies

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Compact 3D Printer Expands Development Firmrsquos HorizonsFor a company that had been using conventional methods of modelling prototypes the versatile rapid prototyping capabilities of Objet Geometriesrsquo office-friendly Eden250 open up lsquoa whole new world of opportunitiesrsquo

An Eden250trade 3D printing system from Objet Geome-

tries installed at the UK injection moulding facility of Ison Products Ltd is being successfully deployed to accelerate time-to-market for a number of the engineering com-panyrsquos high-profile projects High Wycombendashbased Ison is an estab-lished name in both OEM and subcontract product design and development The enterprise will tackle any project regardless of complexity

The office-friendly Eden250 is designed to bring high-accuracy rapid prototyping capabilities within reach for the design or produc-tion department of nearly any compa-ny The prototyping operation is based on Objet Geom-etriesrsquo innovative PolyJettrade technol-ogy which enables the generation of horizontal lay-ers as thin as 16 μm and part walls down to 06 mm thick and allows typical tolerances of 01 mm The easy-to-use machine employs a clean process that involves no special electrical ventilation or material storage requirements Objetrsquos UK distributor OPS Ltd installed the Ison machine

Modernizing PrototypingldquoBefore acquiring the Eden we were modelling prototypes using

fairly conven-tional meth-odsrdquo The per-son speaking is Ison Prod-uctsrsquo manag-ing director

Paul Isaacs ldquoFurthermore tradi-tional toolmaking can take days or even weeks and doesnrsquot come cheap The idea of achieving both reduced lead time and reduced costs made me think seriously about installing an in-house 3D printing resourcerdquo

Isaacs first considered a desk-top 3D printer offered by another manufacturer but component tri-als did not live up to the bro-churersquos promises and excessive hand finishing was required fol-lowing part build Meanwhile he had contacted OPS who rec-

ommended the Eden250 ldquoI was blown away by what it could dordquo Isaacs remembers ldquoThere was no doubt in my mind that it was the right machine for Isonrdquo

Ison uses SolidWorks 3D CAD software and saves files in STL for-mat for transfer to the Eden250 Isaacs explains Using Objetrsquos 3D Studiotrade software the company selects a preferred part orientation and then lets the machine do the rest The Eden250 automatically decides which position on the build platform is best for a particular part Since installation the printer has been producing a vast range of proto types for Ison and its custom-ers in diverse industry sectors

The printer can generate one large model or multiple smaller models within its 250 x 250 x 200-mm build envelope all in a

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

Case Studies

raquo Objet Geometries GmbHRheinmuumlnster Germanywwwobjetcom

single cost-effective time-saving build cycle The user is able to choose from a selection of high-speed high-quality printing modes to optimize the process according to requirements

With dual material cartridges each holding 2 kg the Eden250 is designed for high productivity with little operator intervention Efficient material usage is ensured by Objet Geometriesrsquo PolyLogtrade materials management system

The Objet Eden250 supports four modelling mate-rials FullCurereg 720 transparent VeroBlue Vero White and VeroBlack This selection provides a broad appli-cation range Users can produce models and parts that vary in terms of flexibility elongation at break and colour

New OpportunitiesldquoThe machine has opened up a whole new world of opportunities for Isonrdquo says Isaacs According to the managing director it helps the company think outside the box and come up with unconventional solutions

For example one Ison customer wanted to proto-type a rubber seal for a drinking vessel with a vacu-um casting but replicating the production material proved difficult Isaacs then deployed the Eden250 to print a set of plastic injection-mould toolsmdashdie and cavity Ison was able to inject the seal mould with the very rubber intended to be used for production Because of the materialrsquos low melting temperature it didnrsquot damage the mould tool

ldquoThe customer was thrilled that we could provide a prototype so quickly in the exact production mate-rial and for such a low pricerdquo reports Isaacs who says that considerable amounts of time and money have been saved on other projects by making a similar substitution for metal investment casting tools

Other benefits accruing to Isonrsquos customers from receiving quickly produced 3D prototypes include early validation of design intent enhanced mar-keting presentations and accelerated customer and vendor feedback

ldquoThe acquisition of the Objet machine means we can make real parts in real materials in a matter of hours at a fraction of normal costrdquo Paul Isaacs says ldquoParts that are complex to make using conventional manufacturing methods are ideal for 3D printing The process adds a whole new facet to our portfolio of services and can only help strengthen our position in the marketrdquo

Is pitting in the cavity causing you to rework

molds POCOrsquos EDM materials offer superior

product consistency unmatched EDM perfor-

mance and exceptional cost of ownership

Need reliable EDM results every time

Depend on us

Visit wwwpocoedmcom to find out how our

technical support services can help optimize your

settings to maximize your graphite performance

WHEN YOUR REPUTATIONIS ON THE LINEDepend on us

wwwpococom

POCOreg is a registered trademark of Poco Graphite Inc

ISO 90012008 amp AS91002004

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

40

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Many automotive interior compo-nents are plastic parts that must fit with perfect accuracy for both func-tional and aesthetic reasons These parts are subjected early on to exten-sive dimensional checking by means of either gauges or measuring pro-cesses employing tactile or noncon-tact technology To ensure mean-ingful results in measuring their

accuracy the parts are mounted on special fixtures for dimensional mea-surement These fixtures are usually custom built to optimize access to measuring points Here Horst Witte Geraumltebau Barskamp KG contributes with its Alufix modular fixturing sys-tem that enables custom fixtures to be assembled on the spot without any lead time

The modularity of the Alufix pro-gramme allows the user to adapt the system to changes in part design quickly via a few manual operations The system consists of various high-accuracy high-tensile aluminium components that can be used and reused for years without loss of qual-ity The many different elements and multiple application possibilities for each element provide extensive assembly flexibility Through-bores

in Alufix bars support a diversity of arrangements using integrated con-nection technology

Since Alufix components are made from high-tensile aircraft aluminium assembled fixtures are not only stable but light

Alufix fixtures are designed to be able to hold plastic parts securely but without tension Thus such rela-tively soft and unstable parts are not deformed and measurements will be accurate After use the fixtures can be disassembled and the components applied to new purposes The system comes in different sizes which can be used in combination

raquo Horst Witte Geraumltebau Barskamp KG

Bleckede Germanywwwhorst-wittede

Modular Aluminium Fixturing Optimizes the Checking of Parts for Passenger Car Interiors

The Self Centring Vise 148 from Erowa AG is designed to enhance flexibility in the machining of com-plex workpieces while reducing machine setup times Using longitudi-nal grooves and dowel holes the cen-tring vise can be clamped and positioned easily and quickly either on an Erowa adapter pallet or directly on the machine table It is suitable for use on vertical and horizontal machining centres in production as well as in tool mould and fixture construction

The slides and base body of the vise are manufactured from a single piece This construction is ideal for high cyclical loads on 5-axis machines The entire vise body is made from

stainless hardened steel In addition the slide and spindle have a high-tech coating and offer wear-free perfor-mance The vice is entirely sealed to

prevent chip ingress no matter how much debris is present

The visersquos jaws can be positioned with a grid spacing of 15 mm They can be set up easily by hand without

the use of any tools and the cen-tre can be adjusted externally with screws

The Self Centring Vise 148 is able to clamp workpieces

ranging from 5 to 155 mm in dimension with a repeatabil-ity of 001 mm It is available also with an integrated Erowa

G or P pallet

raquo Erowa AGBuumlron Switzerlandwwwerowacom

Self-Centring Vise for Machine Tables and Pallets Provides Flexible Work Holding

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

MyWorkPlan job-shop software from Sescoi is not only a labour- saving alternative to the manual gen-eration of quotations job records and invoices but an automated job man-agement system as well suited for streamlining processes for business-es such as mould making enterpris-es that are characterized by one-off and small-series productions It also helps optimize customer relations The customizable software is easy to use and its installation is straightfor-ward Companies beginning to use MyWorkPlan can load historical data into the system at the outset Sescoi provides service support thereafter

Software to Automate Job Management Brings Better Efficiency Customer Relations

raquo Sescoi International SASMacon Francewwwsescoicom

The software has a time-saving quo-tation template into which labour and material calculations can be placed It records all the information in its data-base and produces a PDF version of the quotation for the customer

Once the moulder has been award-ed the job MyWorkPlan automati-cally creates a sales order contain-ing an estimate of the hours neces-sary to complete the job the material required and notes for production In addition the software produces an order confirmation for the customer and a reference book containing job notes for engineers on the shop floor

MyWorkPlan also creates invoices automatically from labour and mate-rial data in the system Another ben-efit is immediate detection of time overruns for quick correction

Products amp Services

PE Schall GmbH amp Co KG Tel +49 (0) 70259206-0 middot fakumaschall-messende

FRIEDRICHSHAFEN18 ndash 22 Oct

2011Made by Fakuma

wwwfakuma-messedewwwschall-virtuellde

The Worldlsquos Top Trade Fair for Injection Moulders

The cutting-tool and tooling system special-ist Sandvik Coro-mant has introduced a new range of small CoroMill Plura ball-nose end mills for profiling components made from medium-hard to hard steels The end mills which come in diameters of 01 to 12 mm are very well suited for machining all small dies and moulds components electronic fibre-optic connectors and dental implants They are a natural choice for small-scale applications in which high precision is a requirement

raquo Sandvik Coromant EuropeZaventem Belgiumwwwsandvikcoromantcom

End Mills Are Designed to Profile Small Parts from Steel

Produced in a fine-grained sol-id-carbide grade

with a multilayer coating applied via physical vapour deposition CoroMill Plura end mills feature a specially designed geom-etry that prevents the radius from deteriorating as a result of uneven wear Furthermore the toolrsquos long neck offers good accessibility espe-cially in pocket milling applications

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

42

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

TopSolidrsquoCam 2011 CAM software the latest version of the machining solution from Missler Software that calculates tool paths for numerically controlled milling machines lathes and machining centres offers many new functions especially for users in the tool and mould making and aero-space industries Such innovative func-tions as morphing machine replace-ment Z-level helical machining and

Z-level finishing cycles help ensure excellent part-surface quality and short machining times

Morphing is a 3D operation that creates a tool path from two curves opened or closed The idea is to deform the exterior curve into the inte-rior curve by using interme-diary curves with the result

being one continuous helical tool path that maintains scallop height as it goes Because it uses only a single tool path that is constantly in con-tact with the material this new func-tion in TopSolidrsquoCam 2011 greatly improves the surface quality of parts and may even eliminate the need for polishing

A new wizard in the latest edition of TopSolidrsquoCam lets the operator replace the machine being used with any other machine (see image) Operations that are not possible to perform on the replacement machine are inactivated This function allows great flexibility and potentially better efficiency in the utilization of machines in the workshop

Z-level helical machining maintains constant contact between the tool and the workpiece material Thus by preventing ldquosewingrdquo marks caused by multiple entry and exit moves it is another means of optimizing sur-face quality Z-level finishing cycles allow machine operators to carry out finishing operations on the thin and fragile pocket walls commonly found in aerospace parts regardless of pocket depth These cycles help prevent unnecessary weakening of the already thin walls and reduce pro-gramming times significantly

New CAM Software Functions Optimize Part Surfaces and Calculation Speeds

raquo Missler SoftwareEvry Francewwwtopsolidcom

Product Developmentand Additive Manufacturing

2011

27-29th SEPTEMBER

NEC BIRMINGHAM

Register now

wwwthemanufacturingeventcom

wwwtctshowcomSupported by

7 Events3 Days1 Venue

Free Admission Free Seminars Parking Paid For

Investing in Manufacturing

[ Additive Manufacturing ]

Prototyping

Inspection amp Metrology

Software

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

43

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

To help manufacturing companies deal with a particular problem caused by cutting-tool breakage Heun GmbH a producer of machine tools and accessories offers the TR100 broken-tap remover This compact lightweight portable device provides a highly efficient and cost-effective means of quickly extracting a drill bit that has broken off and become stuck in a hole in the workpiece

Depending on the workpiece mate-rial and the size and form of the broken screw tap removal of such a remnant from a workpiece can be very difficult The easy-handling TR100 however is designed to make the removal of such tool fragments easy Offering all-around applicabili-ty Heunrsquos high-performance machine can reliably deal with both large and

raquo Heun GmbHKahlMain Germanywwwheun-gmbhde

Special Unit Removes Broken Drill Bits from Workpiece Holes

small workpieces and level or inclined workpiece surfaces It fea-tures a swivelling head that enables machining positions usually difficult to access to be reached

The Heun TR100 drill bit remover uses ordinary supply water (tap water) as the machining dielectric fluid and any brass or cop-per electrode up to a maximum diam-eter of 65 mm may be employed The machine can remove the broken tool piece without damaging the hole thread

In addition the TR100 can be placed into service to produce start holes for wire-EDM cutting opera-tions and to cut workpieces made of carbide or any hardened steel The devicersquos complete range of functions includes autofeed auto retract depth

setting (programming to stop at a specific depth) and selectable arc tim-ing as well as work-head swivelling Alarm messages alert the operator to arrival at the programmed depth and warn of arcing or overheating

The generator unit of the TR100 broken-tap remover weighs 17 kg and the work head weighs 6 kg with its magnetically mounting stand

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

44

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Economical CMM-Manager 30 for Windows 7 tactile inspection soft-ware from Nikon Metrology NV runs on nearly all CNC and manu-al coordinate measuring machines (CMMs) Its modern and intuitive Windows 7 graphical interface makes the software highly informative and interactive CMM-Manager automates serial inspection but it also can save money by making it easy to take a few points on the spot When com-bined with the Renishaw PH20 5-axis probe head this version accelerates inspection jobs considerably

In CMM-Manager 30 for Windows 7 the dashboard has been upgraded with intuitive new icons and with a ribbon barndashstyle layout The new ver-sion also incorporates touch-screen and multitouch support plus intuitive navigation paths The user can simply

Big energy savings in machining oper-ations can be achieved with inte-grated tooling solutions offered by Mapal Praumlzisionswerkzeuge Dr Kress KG In one application involving the manufacture of automotive gearboxes for example enhanced tooling from Mapal resulted in a company saving more than 8500 kWh per year equivalent to the emission of 49 tonnes of CO

2 For that manufactur-er Mapal developed a combination tool that machined seven dif-ferent features and replaced four separate tools that previously

walk up to the CMM quickly align the part and immediately measure geo-metric features and points on planes When CAD is available snap point measurements can be taken on the screenmdashmanually probing the work-piece is unnecessarymdashand dimen-sional charts with colour-coded point deviations automatically created

A serial inspection routine that runs on any brand of CMM is easy to pro-

were employed Its introduction elim-inated 388 hours of machine running time annually

Mapalrsquos integrated tools allow sev-eral bores chamfers and flat surfac-es to be machined completely in a

single operation This typically means that four or more tool

changes can be eliminated that machining cycles can be dramatically shortened and consequently that

the machining centrersquos energy consumption for the particular project can be reduced by a considerable amount

Mapal also deliv-ers energy savings by providing tools that

duce with CMM-Manager 30 for Windows 7 In addi-tion automated inspection results in graphical part-to-CAD comparison The soft-ware operates on a PC or laptop running a Microsoft Windows 7 32- or 64-bit operating system

The PH20 probe head that this version of CMM-

Manager supports provides fast infinite rotary positioning for high-speed point measurement with mini-mal CMM movement It brings 5-axis inspection capability to smaller CMMs by optimizing the working volume of the measurement platform

accommodate higher feed speeds For example the Mega-SpeedDrill and the FeedPlus multitooth reamer typically cut machining times in half Higher speeds are very energy effi-cient especially in machining large workpieces and when lightweight tools with optimized cutting-edge geometries are used In addition minimum-quantity lubrication and dry-cutting techniques supported by Mapal technology can provide even greater energy savings as they elimi-nate the need for electrically driven coolant systems

raquo Nikon Metrology NVLeuven Belgiumwwwnikonmetrologycom

raquo Mapal Praumlzisionswerkzeuge Dr Kress KGAalen Germanywwwmapalcom

Windows 7ndashStyle User Interface Makes CMM Software for Tactile Inspection Fast Intuitive

Integrating Tool Technologies Leads to Energy-Efficient Machining and Time Savings

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

13 13

$$amp

1313 $amp1313

13

13(13)

13+

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

46

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

The Mantis Elite-Cam stereo inspec-tion system from Vision Engineer-ing Ltd comprises a standard Man-tis Elite stereomicroscope and a USB20 digital camera integrat-ed and sealed at the factory that allows instantaneous and simultaneous optical and digital viewing Recently Vision Engineering intro-duced ViFox and ViAxos software options for the Mantis Elite-Cam Both options enable images to be stored as JPG BMP or PNG files and provide 2D measurement of features such as lines circles areas and angles With available camera options users can adjust such parameters as brightness and contrast for image enhancement

Intuitive ViFox software lets the user establish key parameters while viewing a live image providing fast precise imaging of samples and com-ponents Images can be captured documented and archived immedi-ately Offering ease of use and fast

navigation ViFox available in Eng-lish German Spanish and Italian is a good choice for quick easy image capture file sharing and on-screen measurement

The alternative Mantis Elite-Cam software ViAxos provides such advanced 2D measurement options as feature-to-feature measurement along with digi-tal zoom to enable individu-al features to be inspected in greater detail Measurement

data can be exported into Excel for further analysis ViAxos is offered in English German French and Italian

Software Options for Stereomicroscope System Provide Instantaneous Digital Image Capture

raquo Vision Engineering LtdWoking Surrey UKwwwvisionengcom

The achievement and main-tenance of tool accuracy is vital in machining intricate workpiece features and high-precision complex parts But successful tool accuracy mea-surement depends on the capability of the measuring equipment and on whether chips debris or coolant on the tool skew measurement results The problem of the machine control being given incorrect data because of this may or may not be solved by blasting the tool with air A surer way to address it is with the ITM intelligent tool mea-surement system now avail-able on a range of high-speed milling machines from GF AgieCharmilles

The ITM system which has won an innovation award provides opti-cal tool measurement at full spin-dle speed Image sensors on GF AgieCharmilles machines measure the tool and analyze its length diam-eter tip quantity and quality radius and other characteristics The data gathered are compared against the baseline image of the tool the values of which have been input previously Such reference data enable the ITM system to subtract the debris or other contamination from the milling or drilling tool digitally and thus deter-mine its actual geometry with accura-cy providing an absolute Z-reference in the micron range

Accurate Camera-Based Tool Measurement System Supports Machining Process Reliability

raquo GF AgieCharmillesLosone Switzerlandwwwgfaccom

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

47

Products amp Services

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

A new version of the proven Leitz-brand LSP-S4 coordinate measuring machine (CMM) measurement head has such a low trigger forcemdashdown to 0005 Nmdashthat a part incurs no scratch marks or other damage when it is being inspected The LSP-S4 Ultra Low Force measurement head is available now on the Leitz Infinity CMM from Hexagon Metrology This accessory would typically be used for the inspection of components with delicate or reflective surfaces such as coated lenses and highly polished high-precision copper titanium or aluminium parts that must be mea-sured accurately and by means of tactile sensors

The Leitz Infinity henceforward has vision metrology capability also For this the stylus of the LSP-S4 or LSP-

S4 Ultra Low Force is automatically replaced with a Precitec chromatic white-light (CWS) sensor The optical CWS sensor is based on the chromat-

ic confocal measurement technique the advantage of which is assured high-precision measurements wheth-er the surface is inclined reflective or dispersive High axial resolution also is available this supports the mea-surement of complex structures The capability of the high-precision CWS sensor derives from its complete tol-erance of variations in ambient light

Further in news of the Leitz Infinity an additional machine with a small-er z-dimension is forthcoming and will offer greater measuring flexibil-ity The new model will be able to be used in measuring facilities that have lower ceilings

raquo Hexagon MetrologyUnterentfelden Switzerlandwwwhexagonmetrologycom

High-Accuracy CMM Has a New Optical Sensor and a More Refined Touch in Tactile Inspection

1313 131313

13

CO LD B LO C K FO R LR S I N J E C T I O N

- With open or closed nozzles - Electrical sealing - Hot runner systems - Built to specifi cation - Standardised elements

S I L I C O N EI N J E C T I O N

See you at

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

48

Products amp Services

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

Trumpf Laser- und Systemtechnik GmbH offers many different laser technologies for weld-ing cutting and marking and thus ultimately enabling customers to produce innovative new product designs efficiently To ensure that it can supply an appropriate laser for every application the company now provides fibre lasers (TruFiber) in addi-tion to disk (TruDisk) diode (TruDiode) rod (TruPulse and TruMicro) and CO2 (TruFlow and TruCoax) types Customers

can use the fibre models for applica-tions in the multikilowatt range for precision processing and micropro-cessing and for laser marking

Because Trumpf is a one-stop shop for beam guidance processing optics and control and automation elements customers can be confident that all components are fully compatible

The laserrsquos application range as a material-processing tool is essential-ly universal but the road to using it in integrated application solutions is highly individual The workpiece to be processed specific application type of material material flow mate-rial strength accuracy desired batch size part variety reproducibility and part costs are all criteria that Trumpf and the customer must discuss thor-oughly in order to arrive at the opti-mal cost-effective solution

To give users strong support in selecting an appropriate laser beam source Trumpf offers its experience and expertise through application centres sited around the world In these centres laser customers can get help in identifying the right laser beam sources for their applications and in aligning production systems with each other optimally

raquo Trumpf Laser- und Systemtechnik GmbHDitzingen Germanywwwtrumpf-lasercom

Diverse Range of Lasers Is Backed by Application Centres for User Support

TRU

MPF

GRO

UP

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

49

ISTMA

wwwetmm-onlinecom | May 2011 | European Tool amp Mould Making

The International Special Tooling amp Machining Association (ISTMA) is a well-established international orga-nization representing more than 30 nationsrsquo special tooling and machining organizations across three continents North America Europe and Asia

ISTMA Europe represents the in dustry in matters concerning indus-trial relations in the European Union

Directory of ISTMA Europe Member AssociationsAmong its many activities it conducts a dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector promotes communication among its members on a wide variety of industry con-cerns maintains an information pool on technical investigation subjects and transfers performing manage-ment actions among its member asso-

CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr Vaclav Klickavaclavklickasvaz-nastrojareneuCeskoslovenske Armady 118156215 Usti nad OrliciTel+420 465 557101 middot Fax +420 465 525128wwwsvaz-nastrojareneu

ESTONIAEstonian Special Tooling AssociationMr Andres PahlapuuandrespahlapuuautolivcomLaki 14 middot 10621 TallinnTel +372 620 5902 middot Fax +372 620 5901wwwemliitee

FINLANDTechnology Industries of FinlandMr Veli Matti Kuismaveli-mattikuismatechindfiEtelaumlranta 10 middot 00130 HelsinkiTel +358 9 1923373 middot Fax +358 9 624462wwwtechindfi

FRANCEAFIM (Association Franccedilaise des Industries du Moule Modegravele et Maquette)Mrs Catherine Larroqueafimufimocom3941 rue Louis Blanc middot 92400 CourbevoieTel +33 1 47176412 middot Fax +33 1 47176360wwwafim-francecom

GERMANYVDMA Die and MoldDr Wolfgang SengebuschwolfgangsengebuschvdmaorgLyoner Strasse 18 middot 60528 FrankfurtMainTel +49 69 66031251 middot Fax +49 69 66032251wwwvdmaorg

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr Saacutendor Markos middot szmszszmszhuLomb u 31C middot 1139 BudapestTel +36 1 3402972 middot Fax +36 1 3295425wwwszmszhu

ITALYUCISAP (Unione Costruttori Italiani Stampi amp Attrezzature Precisione)Mrs Fausta Antinori middot infoucisapitViale Fulvio Testi 12820092 Cinisello Balsamo (MI)Tel +39 02 262551 middot Fax +39 02 26255214wwwucisapit

LATVIALatvian Tool and Prototype Producer AssociationMrs Natatildelija Ivanova middot infolipralvKurzes str 2c middot Riga 1046Tel +371 678 07794 middot Fax +371 678 07780wwwlipralv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr Maksymilian Tomaszewskistowarzyszenie_sttswpplReguly ul Graniczna 1005-816 MichalowiceTel +48 22 7233812 middot Fax +48 22 7235201wwwsttscompl

PORTUGALCefamol (Associaccedilao Nacional da Industria de Moldes)Mr Manuel Oliveira manueloliveiracefamolptAv D Dinis 17 Aptdo 2572430-263 Marinha GrandeTel +351 244 575150 middot Fax +351 244 575159wwwcefamolpt

SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms Janja Petkovsek middot janjapetkovsekgzssiDimiceva 9 middot 1504 LjubljanaTel +386 158 98308 middot Fax +386 158 98100wwwposvet-orodjarstvocom

SOUTH AFRICAToolmaking Association of South Africa (TASA)Mr Grant Stevenson middot grantswctiwebcozaSAS Naval Base Northlink College 50101 J Diesel Block Wingfield Vanguard Drive 7460 Goodwood Cape TownTel +27 21 5923695 middot Fax +27 21 5948155wwwtasawebcoza

SPAINFEAMM (Federacioacuten Espantildeola de Asociaciones Empresariales de Moldistas y Matriceros)Mr Josep Font middot infofeammcomParc Tecnologravegic del Vallegraves Ceramistes 208290 Cerdanyola del Vallegraves (Barcelona)Tel +34 93 5944747 middot Fax +34 93 5944737wwwfeammcom

SWEDENSvensk Industrifoumlrening (SINF)Mr Niklas Eidersjo middot janlarssonsinfseFleminggatan 14 PO Box 22307104 22 StockholmTel +46 8 4401170 middot Fax +46 8 4401171wwwsinfse

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr Peter Vogel middot pvogelswissmemchKirchenweg 4 middot 8032 ZuumlrichTel +41 44 3844811 middot Fax +41 44 3844846wwwswissmemch

TURKEYTool Manufacturersrsquo Association of Turkey (UKUB)Mrs Solmaz Ugurlar YildirimsolmazmoulduniontrcomMustafa Karaer Cad Cigdem 2 SokPK41 DOSAB BursaTel +90 224 2116178 middot Fax +90 224 2114564wwwukuborgtr

UNITED KINGDOMGTMAThe National Metalforming CentreMs Julia Moore47 Birmingham RoadWest Bromwich W Midlands B70 6PYTel +44 121 6016350 middot Fax +44 121 6016378admingtmacouk middot wwwgtmacouk

For information contactMr Fausto RomagnaniSecretariat ISTMA Europeco Cefamol middot Av D Dinis 17 Aptdo 2572430-263 Marinha Grande PortugalTel +351 244 575150 middot Fax +351 244 575159istma-europeistma-europecomwwwistma-europecom

ciations In addition the organization supports European fairs and exhibi-tions focusing on special tooling

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

50

Company Index

European Tool amp Mould Making | May 2011 | wwwetmm-onlinecom

AMB 2012 7

Asiamold 2011 14

Boride Engineered Abrasives 47

CNC Software Inc 7 10

Cumsa 24 29

Dassault Systegravemes 9

DEMAT GmbH 31

Deutsche Edelstahlwerke GmbH 13

DME Europe 18 22

Eberhard Werkzeugtechnologie 15

EMO Hannover 2011 33

Erowa AG 40

ETMM 51

etmm-onlinecom 6 50

Euro PM2011 45

EuroMold 2011 11

Exhibit amp More AG 12

Fakuma 2011 41

FIP Solution Plastique 2011 15

GF AgieCharmilles 46

Guumlhring oHG 30

Hasco Hasenclever GmbH + Co KG 15 21

Hauzer Techno Coating BV 28

Heitec Heisskanaltechnik GmbH 27

Heun GmbH 43

Hexagon Metrology 47

Horst Witte Geraumltebau Barskamp KG 40

Husky Injection Molding Systems SA 8 20 52

Maumlnner Solutions for Plastics 19

Mapal Praumlzisionswerkzeuge Dr Kress KG 44

Mastip Technology Ltd 21 26

Messe Duumlsseldorf GmbH 17

Meusburger Georg GmbH amp Co KG 1 14 16

Millutensil Srl 34

Missler Software 42

Mitsubishi Carbide 3

Mould Eurasia 2011 48

Nikon Metrology NV 44

Objet Geometries GmbH 37 38

Poco Graphite SARL 39

Progressive Components Europe Ltd 2

Rabourdin Groupe 20 47

Rainer Knarr Vertriebs GmbH 11 18

RosMould 2011 7

Sandvik Coromant Europe 10 41

Segoni AG 32

Sescoi International SAS 41

SolidCAM GmbH 8

SSAB Oxeloumlsund AB 36

Strack Norma GmbH amp Co KG 10

Synventive Molding Solutions GmbH 19

TCT Live 2011 42

Thermoplay SpA 43

Toolex 2011 12

Trumpf Laser- und Systemtechnik GmbH 48

Tuumlrk + Hillinger GmbH 5

Vision Engineering Ltd 46

COMPANY PAGE NOCOMPANY PAGE NOCOMPANY PAGE NO

Advertisersadvertisementsshown in colour

Free weekly e-newsletter

wwwetmm-onlinecomsubscribeetmmnewsletter

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index

ETMM the comprehensive trade

magazine for Europersquos tool amp mould

making industry

introduces a new look in 2011

Start your free subscription todaywwwetmm-onlinecomsubscribeetmm

EUROPEAN TOOL amp MOULD MAKING

infoetmm-onlinecom

  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index
  • Editorrsquos Message
  • Table of Contents
  • Industry News
  • Cover Story | Interview
  • Cover Story | Product Focus
  • Cover Story | Quick Sourcing Grid
  • Technology
  • Case Studies
  • Products amp Services
  • ISTMA
  • Company Index