Vision 3D’s modeling function, featuring customized defaults for faster weld path development, creates accurate 3D models using data gathered by weldpiece scans. Welding schedules are met with little or no delay, keeping the shipbuilding operation moving efficiently. An intuitive, easy-to-use interface enables team members at any skill level to learn the software, an especially valuable feature that enables manufacturers to meet the challenges faced when there is a lack of skilled workers on-site. Additionally, shipbuilding sites can be hazardous workplaces with personnel performing welds within closed or close-knit spaces with harmful fumes resulting from weldpiece materials. A Pema automated welding solution equipped with the Vision 3D software allows the welder to move out of these spaces and into the operator’s seat for a healthier work environment.

Pema Vision 3D seamlessly connects with existing Pema automated welding systems for continuous workflow, including the PEMA Vision Robot Welding Portal (VRWP) for shipyards, a compact system developed for micropanel and sub-assembly welding. Due to its size, the VRWP can be commissioned and ramp up completed in just one week, with another week necessary for training. The VRWP series comes equipped with PEMA’s WeldControl 200 software and is fully compatible with the Vision 3D software. Together, PEMA Vision 3D software and the VRWP series of robotic welding portals offer shipbuilders the ideal solution to micropanel and sub-assembly welding challenges often experienced during large structure manufacturing processes.

About Pemamek

Pemamek Ltd., founded in 1970, is a global welding and production automation leader. With extensive 54 years of experience in welding and production automation, Pemamek is dedicated to helping heavy fabrication industries, such as shipbuilding, wind energy, heavy equipment, and the power generation industry, to raise the level of productivity.

Pemamek is a family-owned limited company with solid finances (AAA-rated company). Today, Pemamek employs 450 personnel at its headquarters and factory in Finland, and has local offices in the USA, Brazil, Spain, Italy, Germany, and Poland.

The post Pemamak Introduces PEMA Vision 3D Software for Flat Panel Welding Applications Solutions appeared first on IndMacDig | Industrial Machinery Digest.

TwinCAT software’s multi-thread capabilities have long enabled applications to be distributed across multiple cores. TwinCAT Core Boost takes that to the next level by enabling users to configure the clock frequency of individual processor cores. The clock rate per core can be defined for real-time transmission and user-mode applications. Individual cores can operate permanently and in real-time using this “turbo mode.”

TwinCAT Core Boost monitors the permitted power consumption and temperature of each processor core (and of the overall system) to ensure reliable operation even when turbo mode is used. TwinCAT Core Boost currently supports all Beckhoff Industrial PCs with Intel ® Core I processors from the 11th generation onwards.

About Beckhoff

At Beckhoff, automation is our calling. We empower engineers to differentiate and succeed as industry leaders – to harness new technologies, embrace open standards, and solve the world’s most complex problems. Founded and led by engineers, we organically create advanced controls, communication, IoT, and motion technologies that become unique tools for your one-of-a-kind challenges in an age of digital transformation. As a global partner with U.S. headquarters in Minneapolis, we remain committed to sustainability, inclusivity, and support for the people behind the automation. So whether you’re powering the EV revolution, dazzling on Broadway, launching satellites, or harnessing the wind – you can reach new heights for your business, industry, and humankind.

The post TwinCAT Core Boost Accelerates IPC Performance for Next-Level Automation  appeared first on IndMacDig | Industrial Machinery Digest.

1. Attend the Biggest ProMat Yet Featuring Three Show Halls
ProMat is the place where manufacturing and supply chain professionals help build the future of supply chains to discover that trend or technology that will take their supply chain to the next level of success. This year ProMat will be the biggest show yet with a floor plan of 1,200 exhibits expanding over three show halls at Chicago’s McCormick Place.

2. 1,200 Exhibits from the World’s Leading Solution Providers

ProMat 2025 is the only trade show where you can personally see the best solutions and innovations that the industry has to offer in action and where you will meet the leading suppliers in person. Whether it’s a new product or technology, a new process, or a leading trend that’s going to impact the way you do business, you’ll learn about it here.

3. 200+ Education Sessions Led by Industry Experts

ProMat gives you a preview of what’s new and what’s next for supply chains. Education sessions will cover a wide range of topics, from best practices in equipment maintenance and operation to insights on new technologies and leading supply chain trends and developments.

4. Four Cutting-Edge Keynotes to Ignite Your Next Idea
ProMat will feature four powerful keynotes on topics including leadership, the importance of data, the opportunities offered by AI and emerging tech, and the impact of this shift on the industry workforce. Hear from a football legend on team building and get access to the report on supply chain trends and technologies that are transforming our supply chains.

5. Unwind and Have Fun at MHI Industry Night with Jay Pharoah
Unwind with your team and network with your peers at MHI Industry Night featuring food, drinks and entertainment by comedian Jay Pharoah. With six seasons as a cast member of NBC’s Saturday Night Live, Jay is best known for his wide array of uncanny celebrity impressions.

6. MHI Innovation Award Contestants to Spotlight Leading Technology
The MHI Innovation Award serves to educate and provide valuable insights on the latest manufacturing and supply chain innovative products and services. View all award entries to be showcased at ProMat 2025 in categories of Best IT Innovation, Best New Innovation, Best Innovation of an Existing Product and Best New Innovation in Sustainability. The award winners will be announced at ProMat on March 19 during the MHI Industry Night with comedian Jay Pharaoh.

7. Find Your Next Big Idea at the StartUp Pavilion
Discover innovation at its peak in the ProMat StartUp Pavilion, where groundbreaking products and disruptive solutions come to life. Connect with trailblazing entrepreneurs, experience live demos, and witness the future taking shape right before your eyes. Mark your calendar, you won’t want to miss our exhilarating live StartUp Pitch Contest taking place on Tuesday afternoon in the StartUp Theater.

8. Build Lasting Connections at the Women In Supply Chain Forum

Build lasting connections and learn from founder of Inner Workout and award-winning author, Taylor Elyse Morrison at the Women In Supply Chain Forum. Taylor Elyse Morrison will point out the early signs of burnout and help you develop your own burnout prevention toolkit.

9. Elevate Your Supply Chain Career at the MHI Young Professionals Networking Event
Make lasting connections at MHI’s Young Professionals Networking event featuring food, drinks and classic games like shuffleboard, foosball, and billiards. Don’t miss this evening of networking with other young professionals in the material handling and supply chain industry.

10. One Stop Shop for Supply Chain Innovation

Overall, attending ProMat is a valuable investment for anyone in this industry. From seeing the latest equipment and technologies to learning from industry experts and networking with other professionals, ProMat offers a wealth of opportunities for growth and development. So, if you want to stay ahead of the curve and take your business to the next level, be sure to register you and your team for ProMat 2025 — March 17-20 at Chicago’s McCormick Place.

The post 10 Reasons You Can’t Afford to Miss ProMat 2025 appeared first on IndMacDig | Industrial Machinery Digest.

1. Integration with Current Processes and Shop Culture

The first step is to determine how the new tooling and machine will fit into your existing production environment. Too often, the tooling selection process begins after the machine is already on the shop floor, which can lead to inefficiencies. If operators weren’t involved in the purchase decision, this can create unnecessary hurdles as the team works to integrate the machine into established workflows.

Consider the familiarity of your crew with the new machine’s brand, category, or control system. Machines that match your team’s existing expertise often result in smoother transitions. On the other hand, a new machine provides an opportunity to level up your technology and processes. Research the latest tooling enhancements, trends, and capabilities to ensure your decisions reflect advancements in the market. Planning for training and open communication upfront will ensure a successful integration of the new technology into your shop’s culture.

2. Intended Use and Long-Term Goals

What is the primary purpose of the tooling, and how will its role evolve in the next five years? While it’s tempting to stick with familiar options, this is the time to think critically about future needs. For instance, if you’re planning to expand into high-speed or dynamic machining, HSK tool holding systems may be a better fit than traditional CAT systems. HSK solutions excel in high-speed applications and micromachining, offering increased precision and efficiency.

Workpiece materials and your approach to metal removal should also guide your decisions. Do you favor fast, high-feed cuts or deep, heavy-duty operations? Your answers will influence spindle and tooling requirements. For example, BIG-PLUS spindles, a dual-contact system available on machines from over 150 manufacturers, offer increased rigidity and flexibility across various cutting applications. However, to maximize the benefits, you’ll need to pair them with BIG-PLUS tooling instead of standard V-flange tools.

Additionally, cutting applications—whether milling, drilling, or tapping—require specific tooling solutions. Selecting the right tool and holder for each application ensures better performance, reduced wear, and cost savings in the long term.

3. Workpiece Type and Size

The type and size of your workpieces directly impact tooling choices. Aerospace applications, for example, often involve large workpieces but require small, high-precision tools. In these cases, high-speed spindles can lead to faster tool wear, making air-driven spindles or similar solutions ideal for preserving tool life.

Tool rigidity and reach are also critical, especially when dealing with larger machines and smaller tooling. Systems like BIG-PLUS can address these challenges by enhancing stability. Angle heads are another option for applications requiring alternative tool angles, offering machinists the ability to shorten tools while maintaining precision. It’s essential to consult with your machine tool partner to ensure auxiliary systems, such as angle heads, can be seamlessly integrated into the machine’s design.

Accuracy is another key consideration, but it doesn’t rely solely on the machine’s specifications. Workholding repeatability and stability are equally crucial. Even the most advanced machine cannot achieve precise tolerances without the right workholding solutions. To ensure success, evaluate tooling and workholding options alongside machine specifications.

4. Customization and Future-Proofing

Modern CNC machines come with a range of options and customizations to enhance productivity and flexibility. However, these features are best utilized when tooling partners are involved early in the process. For instance, through-spindle coolant systems are invaluable for high-diameter drilling and boring applications, but their effectiveness depends on compatible tool holders. Engaging your tooling partner during the selection process ensures you don’t miss opportunities to optimize machine features.

Automation is another critical consideration for staying competitive. Zero-point clamping systems can enhance repeatability, speed, and accuracy by eliminating the need to unclamp parts during multi-step machining. Presetters can keep spindles running efficiently by taking measurements offline, while intelligent tool management systems integrate with shop floor technologies to streamline operations. Digital tools, meanwhile, enable precise adjustments and data capture, reducing human error and improving overall productivity.

Partnering for Success

Tooling decisions play a vital role in the success of your new CNC machine. By involving a trusted tooling partner early in the process, you can align your tooling choices with machine specifications and production goals, ensuring optimal performance. This collaboration helps you make informed decisions, unlock greater flexibility, and future-proof your investment.

Have questions or need expert guidance? Reach out to us today to get started on building the ultimate machine and tooling partnership for your shop. 

The post What to Consider When Investing in Tooling for a New CNC Machine appeared first on IndMacDig | Industrial Machinery Digest.

Diffusion bonding is an essential joining method used to achieve a high-purity interface when two similar or dissimilar metals require superior structural integrity, and a traditional brazing approach fails to yield quality results. The process involves applying high temperature and pressure to metals mated together in a hot press, which causes the atoms on solid metallic surfaces to intersperse and bond.

Today, much of the innovation occurring in either high-demand or high-quality industrial sectors involves aluminum as one or more of the layers of metals that are bonded. Aluminum, and its broad family of alloys, is prized as a lightweight metal with strong structural integrity, high electrical and thermal conductivity, corrosion resistance, and a malleability that makes it easy to shape.

Aluminum’s unique blend of lightness, strength, and purity makes it indispensable across various industries. In aerospace, its high strength-to-weight ratio is crucial for structural components. For semiconductor equipment, aluminum enables the fabrication of intricate, contamination-free channels essential for gas and fluid flow, avoiding the impurities inherent in traditional joining methods like brazing or welding. Furthermore, aluminum’s compatibility with diffusion bonding allows for the creation of complex cooling channels in high-power electronics, injection molds, and specialized heat exchangers—designs often impossible to achieve through conventional machining.

Unfortunately, the characteristics of aluminum present a challenge for the traditional diffusion bonding process, which involves the application of radiant heat into the metal layers while in a vacuum furnace. Aluminum tends to reflect radiant heat and has a relatively low melting point in relation to the temperatures that must be achieved for proper diffusion bonding.

Engineers cleverly confronted the issue by developing a conductive heating method which more rapidly reaches bonding temperature. This new approach offers an alternative to traditional diffusion bonding by circumventing the slow process of radiant heating structural assemblies in a vacuum environment.

The c.BOND machine utilizes precisely controlled heat conduction, instead of radiation, to enable high speed production of aluminum-to-aluminum, or aluminum-to-dissimilar material parts. After several years of developmental research, the c.BOND tool can now reduce total diffusion bonding process time essentially in half, and thus reducing the energy required during processing by as much as 30%.  This also improves the quality of the bond in certain instances.

Expediting Aluminum Diffusion Bonding

In the traditional diffusion bonding process, a vacuum furnace provides radiant heat to the surface of the part.  Subsequently the heat is conducted through the assembly and transmitted to the faying surface where required. However, when radiation becomes the dominant form of heat transfer, particularly at relatively lower temperatures in vacuum, below 600°C, aluminum’s thermal conductivity is time consuming.

Aluminum excels at conducting heat, particularly at lower temperatures, making it ideal for applications requiring efficient heat dissipation, such as in electronics and automotive components.

“Aluminum’s high reflectivity poses a challenge in traditional diffusion bonding. It’s like trying to heat a mirror with a spotlight – the energy is reflected away instead of being absorbed into the material [using the traditional diffusion bonding process],” says Horst-Gunter Leng, Product Manager, PVA TePla, a global manufacturer of industrial furnaces and PulsPlasma nitriding systems.

Horst-Gunter Leng adds that diffusion bonding of aluminum requires superior temperature control throughout the process. To prevent overheating of the load, slow heating rates traditionally are applied, leading to long process times.

In addition, aluminum alloys have a narrow processing temperature range for successful bonding. When temperatures fall outside that critical temperature band a poor bond is produced.

To overcome the existing challenges of bonding aluminum, PVA TePla and its partner initiated an extensive development program and came up with an innovative solution: integrating heating elements directly into the press platens, explains Horst-Gunter Leng. “This approach speeds up the bonding process, and significantly enhances efficiency by directly transferring heat to the aluminum components.”

The culmination of extensive research and development is the c.BOND machine, features a unique combination of direct conduction heating through the top and bottom platens which are in contact with the assembly. This innovative design ensures bi-directional homogenous heating and more precise temperature at the bonding interface where it is required.

The c.BOND machine utilizes a hot-press tool with advanced software and feedback sensors to achieve micrometer-precise pressure control across the entire component surface. This ensures uniform bonding over large areas. Furthermore, the system allows for selective heating of specific areas, preventing unnecessary heat exposure to other parts of the component.

The high-vacuum atmosphere within the chamber eliminates contamination and prevents voids in the bonded joint.

“With the [c.BOND] the time to heat the part to the ideal temperature for bonding is cut in half compared to traditional radiant heating. With less processing time required, the energy requirements are reduced by up to 30% as well,” says Horst-Gunter Leng. He notes that multilayer stacking is also possible, which can further increase productivity.

The c.BOND  technology demonstrates significant  quality improvement of bonded aluminum components. The technology improves temperature homogenity in the load by 70%, which enhances bonding across the the entire surface. The technology also improves the parallelism of parts by 50%, which enhances the accuracy of geometric dimensions, tolerances, and product specifications.

According to Horst-Gunter Leng, the c.BOND furnace technology by PVA TePla is commercially available today for high volume production. The innovative furnace technology incorporates another feature unique to the industry, utilizing PVA TePla’s proprietary automatic bonding software (ABP).

“With the automatic bonding software, you place your parts in the furnace, input a few parameters such as the size of the bonding area and the software calculates automatically the optimum processing parameters. No specific diffusion bonding knowledge from the operator is required,” says Horst-Gunter Leng.

He notes that the recipes can be modified according to the type of material being bonded, the thickness of the material, its surfaces, and other factors. During the process the software continuously monitors the process in real-time and adjusts parameters accordingly.

A c.BOND unit is installed at a national research facility in Germany, The Günter Köhler Institute for Joining Technology and Materials Testing (ifw Jena) an independent, non-university industrial research institution that conducts research in diffusion bonding, additive manufacturing, brazing, welding, laser processing, material science, and other forms of bonding.

The c.BOND system is compact, requires minimal maintenance, and enables high-volume production of aluminum components for diverse industries. Its benefits are being realized in aerospace, where it creates lightweight yet strong aircraft components. In the semiconductor industry, it provides a cleaner alternative to brazing, eliminating the risk of solder contamination. There is also growing demand for diffusion-bonded aluminum heat sinks, crucial for cooling high-power silicon carbide (SiC) electronics.

Diffusion bonding also has applications for conformal cooling. The concept is to bond layers of sheet metal that contain machined channel/microchannel structures. When combined, the channels provide a path for heat dissipation. Current applications include power electronics for effective heat management and rapid cooling of molds utilized in injection and blow molding processes.

With the size of components continually getting smaller in sectors like semiconductors and electronics, controlling the amount of time, and by extension heat, introduced into the part becomes more critical.

“As the features [of the internal channels] become more miniaturized, it becomes even more important to control the heating during the diffusion bonding process to avoid any distortion in the part,” says Horst-Gunter Leng. “If you can shorten the cycle time, you introduce less heat into the part. This will facilitate creating parts with conformal cooling channels that have finer and finer features.”

Diffusion bonding is increasingly valuable for joining dissimilar metals, such as aluminum to steel or titanium. This allows engineers to design components and assemblies with the best properties of each metal. For example, one metal might offer superior corrosion resistance while the other provides greater strength. This ‘packaging’ of dissimilar metals opens up new possibilities in design, particularly for overall weight reduction of design and enhancing performance in challenging environments.

When joining dissimilar surfaces, a liquid-phase diffusion bonding process is utilized, particularly when the bonding interface extends beyond R&D sized samples. This often involves an interlayer of an alloy that typically melts at the faying surfaces. When the interlayer includes aluminum, the c.BOND can delivery controlled heat to increase the bonding speed.

Although the c.BOND technology is designed to improve the diffusion bonding of aluminum, PVA TePla can design the machine around the specific needs of the customer customized for the alloy, including copper, which has many applications in specialized heat exchanger or for products used in the microelectronics industry.  The company is exploring options to modify the c.BOND to achieve even higher temperatures above the current maximum of 800°C, according to Horst-Gunter Leng.

As diffusion bonding of aluminum gains importance across industries, contract manufacturers and design engineers must embrace the latest advancements to remain competitive. By adopting fast, energy-efficient diffusion bonding technologies for aluminum and other materials, they can unlock higher production volumes, reduce costs, improve or achieve global sustainability targets, and realize increased profitability.

The post A New Patented Approach to Diffusion Bonding Offers Speed and Improved Process Control appeared first on IndMacDig | Industrial Machinery Digest.

In terms of technology, the water cooled AM8300 servomotor series is based on the tried-and-tested AM8000 motor and its advantageous modular system, which allows for a wide range of options while maintaining consistent availability. A seamless portfolio for all applications is formed by five flange sizes, each available in three different lengths. The AM8300 motors can optionally be equipped with a backlash-free permanent magnet holding brake, shaft seal and keyway. Depending on the size, they are available with various feedback systems such as resolvers or batteryless single and multiturn encoders with OCT or Hiperface. With its water cooling system and high IP65 protection rating, the AM8300 is also suitable for demanding environmental conditions – particularly those with high ambient temperatures. Depending on the size, the AM8300 is equipped with a 1/8” or 1/4” thread for connecting the cooling circuit.

The AM8300 motors are designed to work seamlessly with the servo drives from the AX5000 and AX8000 series and can also be paired with suitable accessories such as the AG2300 and AG2400 gear series as well as pre-assembled motor and feedback cables.

About Beckhoff

At Beckhoff, automation is our calling. We empower engineers to differentiate and succeed as industry leaders – to harness new technologies, embrace open standards, and solve the world’s most complex problems. Founded and led by engineers, we organically create advanced controls, communication, IoT, and motion technologies that become unique tools for your one-of-a-kind challenges in an age of digital transformation. As a global partner with U.S. headquarters in Minneapolis, we remain committed to sustainability, inclusivity, and support for the people behind the automation. So whether you’re powering the EV revolution, dazzling on Broadway, launching satellites, or harnessing the wind – you can reach new heights for your business, industry, and humankind.

The post AM8300 Servomotors Set New High-Water Mark for Performance appeared first on IndMacDig | Industrial Machinery Digest.

Siemens, a leading technology company, is introducing the latest version of the Totally Integrated Automation (TIA) Portal at the Smart Production Solutions (SPS) trade show in Nuremberg, Germany. The engineering framework is designed for improving industrial automation processes. By simplifying workflows and increasing efficiency, it enables faster project development.

TIA Portal Version 20 focuses on performance and efficiency enhancements for users, who will benefit from improved time-to-market, increased competitiveness, and agile adaptation to rapidly changing markets. The new version integrates new programmable logic controllers (PLCs) and simplifies handling for engineers.

Rainer Brehm, CEO Factory Automation at Siemens, explains: “Fully integrated automation as offered in the TIA portfolio is the foundation for expanding toward software-defined automation. With TIA Portal Version 20, users can boost the performance across the board and leverage the most modern functionalities of PLCs – including AI, integrated testing and enhanced security.”

Latest PLC integration enhances performance and security

Siemens is addressing the challenges of increasing the performance of industrial production across the entire Siemens Simatic controller portfolio. TIA Portal Version 20 offers extended functions like support for new PLCs with extensive motion control and safety functions, including the latest S7-1200 G2 controller, increased PLC performance with S7-1511/S7-1513, the introduction of the new modular S7-1500 CPUs, a new technology CPU in the highest performance class, and a new software controller CPU. They all provide a human-readable text-based representation of graphical code with TIA Portal Version 20. This ensures the easy use of external tools like GIT or Beyond Compare as well as code generation to make programming more convenient for users.

Security features are also being continuously improved. With TIA Portal Version 20, Simatic PLCs can be connected to the central user management system for the shopfloor. User management access control (UMAC) allows service technicians to easily access their shopfloor devices while using their standard enterprise credentials – without compromising security. UMAC is in turn connected to the standard identity provider service in the customer’s infrastructure: for example, Microsoft Active Directory or Azure ID. This enables administrators to efficiently manage permissions for automation devices in a standard way, exactly like it’s done for software applications in an IT infrastructure.

Performance enhancement across the board

In addition to the new PLC compatibility, improved program optimization options and a faster program runtime analysis for service and maintenance have been implemented, resulting in an additional performance boost. The new version also offers opportunities for greater efficiency when it comes to engineering across different locations: An optimized data exchange between TIA Portal, TIA Portal Cloud and Project Server Cloud ensures seamless collaboration between all platforms. This includes a user-friendly edge app as well as automated cloud backup that ensures the availability of all the latest changes.
Another step toward improved performance is the testing function in the TIA Portal Test Suite where continuous regression tests guarantee reliable code quality for all machines. TIA Portal Version 20 supports test-driven development of the latest S7 programs and sequential testing.

The Siemens Industrial Copilot seamlessly connects generative AI with the TIA Portal to support automation engineers in their daily work. The new version ensures that important function and security updates are incorporated.

The post TIA Portal Version 20: Enabling peak performance and efficiency appeared first on IndMacDig | Industrial Machinery Digest.

Visitors to Fabtech were especially captivated by Cosen’s NC510MG, a fully automatic scissor-style mitering band saw. Marketed as an ideal choice for fabricators looking to elevate productivity, this model stands out for its combination of power and precision. Hayden Peterson, Cosen’s North American Marketing Manager, demonstrated the NC510MG’s robust capabilities, focusing on its user-friendly automation features. “This machine is designed for those fabricators who want to take production to the next level,” Peterson said. With a price point around $61,000, the NC510MG offers features that simplify complex cuts, setting a new benchmark for value in high-demand production environments.

The NC510MG includes a full-capacity top clamp, a standout feature enabling it to securely hold large or bundled materials for high-straightness cuts. For operators managing multiple projects, its fully programmable control system offers storage for up to 100 different jobs. The automated mitering function allows users to pre-program precise angles, minimizing manual adjustments. The ability to input specific degrees—like a 60-degree angle—means the machine handles adjustments independently, letting operators “set it and forget it.” This model exemplifies how Cosen has seamlessly integrated automation into its sawing solutions to meet the evolving demands of modern fabrication.

A Diverse Array of Sawing Solutions

While the NC510MG was a crowd favorite, Cosen also showcased a diverse lineup of models, each catering to unique fabrication needs:

• G320 Fully Automatic Dual Column Band Saw: This saw features a cutting capacity of 12.8″ x 15″, making it a top choice for high-volume production facilities. With its dual-column structure, the G320 maintains exceptional stability and precision during continuous operations, making it ideal for applications that require reliable performance over long shifts.
• AV-2026NC Vertical Tilt-Frame Band Saw: Known for its versatility, this model is a fully automated vertical tilt-frame saw with a 20″ x 26.3″ cutting capacity. It is designed for heavy-duty structural fabrication, particularly where angle adjustments are frequent. The AV-2026NC’s vertical tilt-frame provides ease in cutting large beams and I-beams, meeting the demands of both structural and general fabrication.
• C-300MNC Fully Automatic Scissor-Style Mitering Band Saw: Another fully automated model, the C-300MNC is built for medium-capacity tasks with a cutting range of 9″ x 11.5″. Its scissor-style mitering design allows for easy angle adjustments, making it suitable for smaller but diverse production needs.
• SH-1000F Semi-Automatic Dual Column Band Saw: With a substantial cutting capacity of 20.5″ x 40″, the SH-1000F is designed for cutting large billets. Its dual-column design ensures structural rigidity, making it highly effective for demanding applications like steel construction. Semi-automatic functionality in this model provides operational efficiency without the need for full automation, catering to users who want reliability with a measure of manual control.
• SH-500M Semi-Automatic Scissor-Style Mitering Band Saw: Highly popular among fabricators, the SH-500M features a scissor-style design and miter capabilities up to 60 degrees in one direction, accommodating cuts for complex layouts. With a cutting capacity of 11″ x 19.7″, this model combines functionality with adaptability, handling tasks like flipping parts for opposing angles.
• SC-350 Semi-Automatic Circular Cold Saw: This circular cold saw caters to smaller production operations, with the ability to cut both solid materials (up to 2.362″) and tubing (up to 4.331″). The SC-350 is valued for its precision in making clean cuts on smaller stock, from tubing to metal bars, fitting seamlessly into shops with more specific cutting needs.

Emphasis on Automation and Operator Efficiency

Cosen’s booth not only showcased individual saw models but also highlighted its advances in automation. With new technologies focused on sawing automation integration, Cosen’s solutions improve operator efficiency and streamline production flow. The introduction of programmable mitering, enhanced clamp systems, and job storage across models exemplifies how Cosen meets market demand for higher productivity and minimized downtime. By automating repetitive tasks, Cosen’s machines enable operators to focus on overseeing complex projects rather than making constant manual adjustments, which has become essential in sectors requiring high production and accuracy.

Commitment to Quality and Versatility

Since its founding in 1976, Cosen Saws has been known for its dedication to quality and customer-focused service. The company’s expansive product line—now a staple in North America—covers an array of band saw solutions tailored to both large-scale and specialty applications. Cosen has continually evolved to address the needs of key industries, such as automotive, aerospace, steel construction, and more, offering machines that bring durability, precision, and versatility to the shop floor. Recognized as a top sawing manufacturer in Metal Center News’ Top-10 Equipment Brands survey, Cosen’s reputation for quality has made it a preferred choice among fabricators.

Cosen’s North American headquarters in Charlotte, NC, serves as the company’s central hub for product distribution, service, and support. Maintaining an extensive parts inventory and a team of skilled technicians, Cosen ensures prompt support to minimize downtime for customers. The company’s motto, “Pinnacle of Cutting Performance,” reflects its commitment to helping customers find the right solutions to meet their production needs.

Expanding Cutting Capabilities for the Future

Fabtech 2024 highlighted Cosen’s role as an industry leader in the development of band saw technology, bringing attention to solutions that address modern fabrication challenges. As industries like aerospace, automotive, and construction move toward automation and digital integration, Cosen’s machines are positioned to keep pace with evolving production requirements. The diversity of models on display at Fabtech demonstrated Cosen’s capacity to support applications ranging from simple cuts to complex angled layouts, ensuring precision in even the most demanding settings.

With a foundation of reliability, an expansive service network, and a portfolio that keeps expanding with innovative technology, Cosen remains dedicated to driving the future of cutting solutions. Their continued advancements in automation and user-focused design mean that customers can look forward to machines that don’t just cut but actively enhance production capabilities.

The post Cosen Saws at Fabtech 2024: Showcasing Cutting-Edge Solutions for Precision and Productivity appeared first on IndMacDig | Industrial Machinery Digest.

The Challenges of Traditional Resin Post-Processing

Initially, Prototek relied on traditional isopropyl alcohol (IPA) dunking methods for removing resin from parts. This method, while common in additive manufacturing, presented a range of challenges that impacted both efficiency and quality. Some of the main issues included:

Inconsistency in Cleaning: Resin removal via IPA baths often resulted in inconsistent outcomes due to variances in solvent concentration and the quality of the dunking process. Manual processing, especially in high volumes, led to variability in the surface finish and mechanical properties of the printed parts.

High Solvent Costs and Environmental Impact: Frequent replacement of IPA was necessary to maintain effectiveness. Not only did this contribute to increased operational costs, but the use of large quantities of IPA also raised concerns regarding environmental impact and workplace safety due to the volatility of the solvent.

Quality Control Issues: Variability in IPA concentration and temperature could lead to under-processed or over-processed parts. Insufficient resin removal resulted in compromised part quality and appearance, while over-processing could damage delicate features, making it challenging to maintain a consistent output.

Manual Labor and Time Consumption: The reliance on manual intervention to monitor and execute the dunking process was time-intensive and laborious. A single job required dedicated time and focus from skilled operators, who had to manage multiple variables to achieve the desired finish.

These limitations drove Prototek to seek a more robust, efficient, and scalable solution to meet its growing production needs. After evaluating several options, Prototek selected PostProcess Technologies’ DEMI 910 automated resin removal solution to address these challenges.

Why Prototek Chose the DEMI 910

The DEMI 910, developed by PostProcess Technologies, represented a significant advancement in automated post-processing for resin-based parts. Unlike traditional solvent-based methods, the DEMI 910 offered a closed-loop, automated solution that mitigates the issues associated with IPA dunking. Key features of the DEMI 910 that made it the ideal choice for Prototek include:

Automated Resin Removal: By automating the entire resin removal process, the DEMI 910 minimized human error and manual intervention, allowing Prototek’s operators to focus on other high-value tasks.

Precision with PLM-501-SUB Detergent: The DEMI 910 uses PostProcess Technologies’ proprietary PLM-501-SUB detergent, specifically formulated for elastomeric resin removal. Unlike IPA, PLM-501-SUB is engineered to remove resin at a consistent rate without losing efficacy over time. This contributed to more predictable and repeatable outcomes.

Enhanced Throughput: The DEMI 910 allowed Prototek to process up to three jobs simultaneously, drastically reducing cycle times. With a processing capability of one job per hour, Prototek was able to achieve nearly triple the throughput compared to the previous method, significantly enhancing productivity.

Compatibility with Carbon® L1 Printers: Prototek’s adoption of the DEMI 910 was driven in part by its compatibility with Carbon® L1 printers. These printers are widely used for high-volume, high-quality parts, and the DEMI 910’s advanced automation features seamlessly integrated with Prototek’s existing infrastructure.

Streamlined Workflow and Improved Efficiency

Prototek’s transition to the DEMI 910 resin removal system brought immediate improvements in workflow and efficiency. Before implementing this solution, Prototek faced significant bottlenecks in post-processing due to the manual labor required to monitor and adjust the IPA concentration and temperature for each batch. The automated capabilities of the DEMI 910 allowed Prototek to eliminate these bottlenecks by providing a hands-free solution.

By reducing the need for constant human oversight, Prototek’s team could allocate their time to other essential tasks, such as quality control, part finishing, and machine maintenance. This shift not only improved the company’s efficiency but also resulted in a more streamlined operation, allowing for faster turnaround times and more predictable schedules for customers.

Boosting Consistency and Quality Control

The consistent output from the DEMI 910 addressed the quality control issues Prototek previously encountered with IPA-based methods. Thanks to the PLM-501-SUB detergent’s stability, Prototek was able to achieve reliable, high-quality finishes without risking damage to the parts. The controlled environment within the DEMI 910 prevented issues related to temperature fluctuations and solvent degradation, which are common in traditional dunking methods.

Additionally, the automation provided by the DEMI 910 allowed Prototek to maintain uniformity across multiple batches of parts. This consistency was especially important for Prototek’s clients, who require precision in their components, whether they are used for medical applications or intricate consumer products. With a reliable, repeatable process in place, Prototek established a strong foundation for quality assurance and customer satisfaction.

Sustainability and Cost-Effectiveness

Beyond quality and efficiency, Prototek also considered the environmental and economic benefits of adopting the DEMI 910 system. The PLM-501-SUB detergent’s extended lifespan and lower volatility reduced the frequency of replenishment and the costs associated with solvent disposal. Unlike IPA, which can evaporate quickly and must be frequently replaced, the closed-loop system in the DEMI 910 minimized solvent waste and improved overall sustainability.

By transitioning away from IPA, Prototek also reduced its reliance on flammable solvents, creating a safer and more eco-friendly work environment. These changes not only contributed to cost savings but also aligned with Prototek’s commitment to environmental responsibility, an increasingly important factor for many manufacturing businesses today.

Future Outlook and Potential for Scaling

Prototek’s success with the DEMI 910 resin removal system has encouraged the company to consider additional applications for PostProcess Technologies’ solutions. The scalability and flexibility of the DEMI 910 open new possibilities for expanding Prototek’s capabilities in other areas of additive manufacturing. Prototek has already begun testing the system with new product lines, aiming to explore its utility across a broader range of materials and parts.

With PostProcess Technologies as a partner, Prototek is positioned to continue improving its operations by implementing advanced post-processing solutions tailored to meet the demands of high-volume production. The two companies are working together to identify opportunities for further automation and efficiency gains, potentially integrating additional PostProcess systems as Prototek’s needs evolve.

Conclusion

Prototek’s adoption of PostProcess Technologies’ DEMI 910 represents a transformative step in resin post-processing for additive manufacturing. By addressing the limitations of traditional methods, the DEMI 910 provides Prototek with a scalable, efficient, and environmentally friendly solution that supports consistent, high-quality production. This case study highlights the value of advanced automation in modern manufacturing, particularly in areas where precision and reliability are paramount.

As Prototek explores further applications for this technology, the DEMI 910 stands as a testament to the power of innovation in driving operational excellence. With continued advancements in additive manufacturing and post-processing, companies like Prototek are well-equipped to meet the demands of today’s dynamic market while setting new standards for quality and sustainability in the industry.

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“Innovation and development are fundamental to our success in the cutting tool industry,” said Dan Cope, President of the Americas for CERATIZIT. “Adding Eric to the CERATIZIT team increases our capacity to push the limits of precision and performance for our customers with tools that sustainably boost productivity across a wide variety of industries.”

Gerringer has a strong background in leadership development, training facilitation and manufacturing market forecasting. In addition, throughout his career, Gerringer has remained active on the shop floor. His hands-on machining, CAD/CAM, design and production management proficiencies translate into efficiently identifying cutting tool solutions for customers.

“I am focused on working with people to solve their metal cutting problems,” says Gerringer. “Whether I am helping customers understand why a different tool will improve their process or how a new technology can improve their bottom line, the pay-off comes once the machine is successfully running the tools and our customers see the results.”

About CERATIZIT USA, Inc.

CERATIZIT USA designs and manufactures high quality standard and custom tooling for the metalworking industry. With headquarters in Schaumburg, Illinois, CERATIZIT USA is a solutions and service provider for many different industry segments, including automotive, aerospace, and energy. With a highly specialized staff, expansive product portfolio and an International Traffic in Arms Regulations (ITAR) registration, CERATIZIT USA provides manufacturers with the complete application engineering, service and training support needed for maximum productivity and cost-effectiveness.

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