Volume 20 Issue 2 - Finn-Power International, Inc.

Management Corner
Reflection, Resolution &
Planning
See Page 3
EuroBLECH 2010
“Green Means” from Prima
Finn-Power
See Page 12
Tech Tips...
Finn-Power Turret Flexibility
See Page 2
Increasing Productivity... See Page 4
Discover Lean Manufacturing... See Page 20
Automation Flexibility... See Page 14
Customer Profiles Highlight
Prima Finn-Power’s
Productivity and Flexibility
Volume 20 Issue 2 December 2010
Bending Technology
Analyze the Options...
FABTECH 2010
“Green Means” Makes
Impact in Atlanta
See Page 8
See Page 13
Software Updates
Tulus & NC Express
See Page 18
Tooling Articles…
Mate Precision
Tooling See Page 7
Wilson Tool
International See Page 23
Wila USA See Page 17

TECH TIPS
Finn-Power Turret Flexibility
To maximize Finn-Power turret punch press productivity and flexibility,
the latest series of turrets have several features that are built-in, or can
be added to existing machines.
These features allow the full use of indexable tooling, Multi-Tools and
upforming indexable tools integrated with the Finn-Power NC Express
graphical programming system.
The turret layout for the standard hydraulic or servo electric machine
consists of 20 stations. The linear drive machines have a 24 or 30 station
turret layout.
Turret Layout Tooling Options
Standard 20 station turret
■ A full 33 ton 3.5” (89 mm) indexable station can be in each odd
numbered station
■ Or a fixed Multi-Tool station
■ Or an indexable drop-in 3 station B, or 8 Station A Multi-Tool in the
standard D auto-index stations
■ 5 odd numbered stations can be indexable upform or fixed upform
stations
On the SB and LB the choice can be:
Standard 24 station turret
■ Every station is capable of index, upform and Multi-Tool, both indexible
and fixed
Standard 30 station turret
■ 15 stations are index, or Multi-Tool capable
■ 7 stations are index and upform index capable
The fixed D upform stations can be customized for large form tools
bigger than 3.5” (89 mm) in diameter up to 4.75” (121 mm) in size using a
modified fixed upform holder. This station allows you to have the oversize
form die sit below the die line and form up from it, leaving the turret clear of
the die when retracted.
The custom holder has the flexibility to
allow the use of regular D size form tools, as well
as up to 3” (76 mm) diameter punching tools.
The turret layout for these machines can
also be factory ordered to have special thick
turret E (4.5”) station bores that are nonindexable
for E size form or cluster punch
tooling that the user may have. This enables you
to have one machine with a large tool capacity
capable of even large forms in a single turret.
Below is a turret layout for the latest series of machines with a 20 station
turret showing turret flexibility options which allow greater productivity by
reducing the number of tool change-outs. This is due to the ability to index
form tools rather requiring single tools at fixed positions. You can also have
many full tonnage index stations in the same turret layout, allowing you to
reduce fixed tool numbers saving on both tool change-out time and the cost
of extra tools.
NC Express Turret Layout
This turret layout has:
■ 24-8 mm/0.312” fixed round tools
or shapes at 0.45 and 90 degrees
■ 10-16 mm/0.625” fixed round
tools or shapes at 0.45 and 90
degrees
■ 8-24 mm/0.945” fixed round tools
or shapes at 0.45 and 90 degrees
■ 3 indexable Multi-Tool regular B
station tools (regular B size tools
can be used in this station)
2
by Andrew McCarlie, Applications Engineer
■ 1 B 1.25” indexable upform station
■ 8 indexable Multi-Tool regular A station tool (regular A size tools
can be used in this station)
■ 2 D 3.5” indexable upform full tonnage stations with 2” punching
capacity
■ 1 3.5” regular full tonnage D index station with 3.5” punching
capacity
■ 1 4.75” fixed upform station with 3.5” punching capacity
■ 7 fixed 1.25” B stations
■ 3 fixed 2” C stations
This gives you a total of 68 tools of which 15 are
fully indexable, including 3 index upform stations
and all are full tonnage capable.
The turret has one specially modified fixed D
upform station for a 4.5” knockout tool. The
station can also be used for regular 3.5”(89 mm)
punch tools.
The Index Upform Capability
The index upform option has been designed to be very flexible. It can
operate in several different ways to accommodate the user giving
greater productivity.
These are:
■ As a punching index station with a 2” (50 mm) diameter
maximum hole size capacity unless the tool is a cluster punch. A
special shim and die holder are used when this mode is being
used. The upform mode is not used.
■ An indexable upforming station with the ability to index a shape
and form at full tonnage up to 3.5” (89 mm) diameter up to
0.620” (16 mm) high. The fully controllable lower upform ram is
used here making it possible to form from below the sheet or die
line thereby eliminating scratches and allowing for forms up to
0.620” (16 mm) high.
The Finn-Power index upform lower ram is fully controllable at
maximum forming tonnage as well as indexable and NOT just like the
die retraction function of a fixed or indexable station found on some
machines. The servo-electric option machines lower upform ram can
be controlled in 0.001mm increments. This method of forming allows
you to run sheets faster because you do not have a formed die sitting
high in the turret.
The index upform station allows for the use of rollerball or wheel
technology tools with the ability to program the rollerball/wheel die to
lift up into position before forming the material. It
is retracted after being used.
Both the above abilities of the upform station
to die lift independently of the forming mode allow
the flexibility to leave such tools in the turret where
possible and save time changing out tools.
The FINN-ISH LINE is a publication distributed to PRIMA FINN-POWER
customers, prospective customers, employees, dealers, suppliers and friends. The
staff of the FINN-ISH LINE requests article ideas and letters for future publication.
Editor Robert J. Kolcz rjk@primafinnpower.us
Assistant Editor Diana Vazquez diana.vazquez@primafinnpower.us
Technical Editor Lutz Ehrlich lehrlich@primafinnpower.us
Contributing Editor Andrew McCarlie mccarlie@primafinnpower.us
All registered trademarks in this publication are property of their respective owners.

MANAGEMENT CORNER by John Rogers, COO
Reflection, Resolution & Planning
The Holiday Season is traditionally a time
for reflection and resolution. And in this
still uncertain economy, sheet metal
fabrication shop owners and managers should
not only reflect and resolve, but also take this
time to aggressively plan on how to best position
their companies to have the competitive edge in
the months ahead.
To be sure, there are strong glimmers of
hope of a continued recovery. The large number
of visitors to the Prima Finn-Power EuroBLECH
booth coupled with the fact that we sold a
record amount of equipment during the show
demonstrated strong signs of a resurgence in the
economy. We also experienced a steady stream of
visitors at the FABTECH booth, which was also
very encouraging.
Green Means
Our theme for both shows was Green Means, a
recognition of how during the last decade, Prima
Finn-Power has pioneered servo-electric products
into the sheet metal fabrication industry. We
introduced the first servo-electric turret punch
press – the E5 work center – in 1998. Since that
time, our family of energy-saving products has
grown to the widest offering of servo-electric
technology in the sheet metal fabrication market.
Today, these products include:
■ Servo-electric turret punch press work
centers, including the new cost efficient E5x
■ Laser cutting
■ Servo-electric press brakes
■ Automatic bending
■ Integrated punching and laser cutting cells
■ Integrated punching and shearing cells
We are helping our customers transform their
facilities into Green Factories. And while the lofty
social and ethical values of green manufacturing
are certainly extremely important, there are also
many practical reasons to consider these products.
Sustainability also adds to manufacturing
efficiency and productivity. All Finn-Power servoelectric
machines provide our customers with such
benefits as:
■ Higher precision
■ Higher repeatability
■ Higher quality of end product
■ Less energy consumption
■ Lower maintenance costs
■ Lower operating costs
■ Higher versatility
■ Higher reliability
■ Ease of operation
■ Less noise & vibration
Prima Finn-Power’s servo-electric technology
can produce more accurate, higher-quality parts
while dramatically slashing energy and operating
costs that will add “green” to both your
corporate carbon footprint and company’s
profits. Our Green Means flexibility streamlines
operations and eliminates waste, while matching
the right machine, cell, or system to each
individual customer production need. Whether
your fabrication need is to laser cut, punch,
form, shear, mark, tap, bend, load/unload, utilize
full FMS automation…or anything in-between,
Prima Finn-Power has the flexible manufacturing
solution for your company.
In The Words of Our Customers
This issue of the FINN-ISH Line features several
customer profile articles that highlight how
Prima Finn-Power’s flexibility and technological
advantage have helped customers increase their
quality, productivity, and profits:
Pulverman Precision Metal Components,
Dallas, PA (see page 14) Through its emphasis
on contract manufacturing and diversity,
Pulverman has been able to grow its business
and has experienced double digit growth every
year except in 2009.
■ “We are very impressed with the Prima lasers and
the company’s service. Back in 2004, I never
imagined having three Prima lasers when we
bought the first. Today, I don’t believe we would
ever buy a different brand. We are quite satisfied.
From a service standpoint, there is high level of
responsiveness and a very good relationship that is
very important to us. We also run our machines
very hard, as evidenced in our first Platino,
which has over 46,000 hours of run time.”
Emerson Network Power, Columbus, OH
(see page 20) In 1997, manufacturing managers
at the Liebert Precision Cooling facility in
Columbus, Ohio decided to replace their existing
legacy mechanical turret punch presses. Instead
of merely replacing the mechanical machines
with hydraulic models, the company invested in
Shear Genius flexible manufacturing cells from
Finn-Power. In 2008, the company purchased an
3
automated cell from Finn-Power. The cell
includes the Shear Genius, a picking/stacking
robot, and the EBe automated bender.
■ “We installed the cell in May 2008 and made
production level quantities in August. It has
reduced our setup times dramatically compared
to the 18 minute changeover from our press
brakes. There is a savings of 30% in labor when
running the EBe over the manual brake. In
terms of volume, we can now make a panel
every 40-50 seconds. We make approximately
300 parts per shift, running three shifts during
the week. To date, our cost savings with the EBe
has totaled over $750,000, consisting mostly of
labor savings and setup time reduction.”
Vac-Con, Green Cove Springs, FL (see page 4)
Vac-Con is one of the world’s leading
manufacturers of sewer cleaning and excavating
equipment, producing such products as
combination sewer cleaners, jetters, and
industrial vacuums. After attending trade shows
and doing a great deal of research, Vac-Con
purchased a Prima Platino 2D Laser System with
the 10-shelf TowerServer automated work
handling system.
■ “This system has proven to be one of the better
investments that we ever made. It has allowed
us to gain about a 30-35% increase in
output.”
■ “The Platino’s efficiency has allowed us to take
one of the plasma cutting centers off-line.
During the past four years, we have improved
our manufacturing efficiency by 15-20%. I
attribute a large part of that to the Prima laser
cutting system and tower.”
Happy Holidays from everyone
at Prima Finn-Power!

CUSTOMER PROFILE
Florida Manufacturer Dramatically Increases
Productivity with Automated Laser
Vac-Con, Green Cove Springs, FL, is one of
the world’s leading manufacturers of sewer
cleaning and excavating equipment,
producing such products as combination sewer
cleaners, jetters, and industrial vacuums. Vac-Con
manufactures these products to be sold to
municipalities and contractors across North
America, as well as South America, the Middle
East, and Europe.
Most of the products that Vac-Con
manufactures are cut from steel plate – 20 gauge
up to 2 1 /2 inches. In 2007, Vac-Con’s
management decided that its fabrication shop
needed more capacity. The company had two
large plate plasma cutting centers and a laser
cutting centers on site. After attending trade
shows and doing a great deal of research, Vac-Con
purchased a Prima Platino 2D Laser System with
the 10-shelf TowerServer automated work
handling system.
“The Prima laser system was
responsible for a 30-40%
increase in our productivity.
Approximately 50-60% of all
metal in our shop is processed
by the Prima laser system.”
The Platino is equipped with lasers developed
and produced at Prima Industrie in laser powers
ranging from 3000 to 5000W. The laser cuts a
broad range of materials and thicknesses with
speed and precision without the need for manual
adjustments. Platino’s laser cutting head gives
users a choice of a 10-inch focal length in
addition to the standard 5-inch and 7.5-inch
lenses. The 10-inch lens enhances the application
flexibility by increasing the depth of focus and
enlarging the spot diameter for high and uniform
cut quality of thick stainless (5/8 in), thick
aluminum (1/2 in) and thick mild steel (1 in).
Offering a compact footprint along with a
Cartesian Cantilever structure that provides threesided
access, Platino is a cost-effective machine
that is easy to operate and quick to program. Its
unique stonecast frame reduces vibration and
increases stiffness by about 4 times compared to
cast iron and about 6 times compared to welded
frames. Its low heat conductivity results in much
higher thermal stability compared to traditional
cast or steel frames.
According to Bob Graden, plant manager,
The Platino is equipped with lasers developed and produced at Prima Industrie in laser powers ranging from 3000 to
5000W. The laser cuts a broad range of materials and thicknesses with speed and precision without the need for manual
adjustments.
Vac-Con’s plant manager Bob Graden (right), considers the Prima Platino a wise investment for his company. It has
allowed the company to gain a 30-35% increase in output.
the Prima Platino has been a wise investment for
Vac-Con. “We decided on the Platino because of
its “footprint”, which fit within the production
space of our building,” explains Graden. “As we
researched the laser market, we also discovered
that Platino and the TowerServer was the most
economical system on the market at that time.”
4
Flexible Automation
Prima’s 10-shelf TowerServer allows easy
loading/unloading for blanks and processed
sheets. It has an elevator for loading and
unloading the pallets on and off the tower, and
features single sheet separating, control systems,
and sheet reference. “This system has proven to

“This system has proven to be
one of the better investments
that we ever made. It has
allowed us to gain a 30-35%
increase in output.”
be one of the better investments that we ever
made. It has allowed us to gain a 30-35% increase
in output,” says Graden. “The Prima TowerServer
improves our efficiency to quickly produce parts
and increases our flexibility by allowing us to store
different gauges and types of material. We run
this unit unmanned throughout our 2nd shift.
Before we bought the Prima, we were producing
Platino’s laser cutting head gives users a choice of a 10-inch
focal length in addition to the standard 5-inch and 7.5inch
lenses. The 10-inch lens enhances the application
flexibility by increasing the depth of focus and enlarging the
spot diameter for high and uniform cut quality of thick
stainless (5/8 in), thick aluminum (1/2 in) and thick mild
steel (1 in).
“The Prima TowerServer
improves our efficiency to
quickly produce parts and
increases our flexibility by
allowing us to store different
gauges and types of material.
We run this unit unmanned
throughout our 2nd shift.”
about 80 sheets a week off the two plasma cutting
centers. Now we are cutting anywhere from 200
to 300 sheets per week. The Platino’s efficiency
has allowed us to take one of the plasma cutting
centers off-line. During the past four years, we
have improved our manufacturing efficiency by
15-20%. I attribute a large part of that to the
Prima laser cutting system and tower.”
The TowerServer not only helped produce
more parts for Vac-Con, but allowed the
company to better manage its sheet steel
inventory. “Every day our engineers look at parts
in a different light because we now have
capabilities throughout our laser cutting
operations which allow us to not only to improve
the quality of the part, but in some cases to be
able to combine pieces that we used to have to
make and then weld together,” explains Graden.
“We are able to cut it on our laser cutting center
and then go to our press brake operations and
greatly reduce our welding time and increase the
appearance and quality of parts that we produce.”
Proven Performance
According to Graden, since installation, the Prima
laser system has proven itself time and time again
at Vac-Con. “When we first brought the Platino
online, we had two operators operating the
machine 16-20 hours per day,” says Graden. “As
we gained a better understanding of the machine
and got more familiar with the nesting of the
parts we produce, we found that we could
actually move one of the operators to another
function within the fabrication area. Because we
can run “lights out” with the Prima Platino laser
system, it is nice to come to the shop in the
morning and find parts sitting there ready to go
to other processes. We can now build the trucks
more efficiently.”
Reduced Secondary Operations
The Platino laser system also helped improve
quality at Vac-Con. “We have seen a great
improvement in the quality of parts that come off
the Platino,” explains Graden. “The parts coming
off the plasma cutting machines had to be put
through a secondary operation. We have a
5
Prima’s 10-shelf TowerServer allows easy loading / unloading
for blanks and processed sheets. It has an elevator for loading
and unloading the pallets on and off the tower, and features
single sheet separating, control systems, and sheet reference.
sanding machine that is located next to the
plasma cutting machines, and we had to put all
those parts from the plasma cutter through the
sander. The Prima laser has eliminated secondary
operations in about 99% of the parts that we
process through the Platino.”
The Platino laser system also helped improve quality at Vac-Con. It has eliminated secondary operations in about 99% of
the parts that the company processes through the Platino.

continued from page 5
Increased Productivity
Prior to purchasing the Prima laser system in
2007, Vac-Com produced 18-20
combination machines per month. “Once
we bought the Prima, our on-line efficiency
and production continued to increase until
we were producing between 32-34 units per
month,” reflects Graden. “The Prima laser
system was responsible for a 30-40%
increase in our productivity. Approximately
50-60% of all metal in our shop is processed
by the Prima laser system.”
“The Platino’s efficiency
has allowed us to take one of
the plasma cutting centers
off-line. During the past four
years, we have improved our
manufacturing efficiency by
15-20%. I attribute a large
part of that to the Prima
laser cutting system and
tower.”
Vac-Con decided to purchase the Platino because of its
footprint, which fit within the production space of its
building. As the company researched the laser market, it
discovered that Platino and the TowerServer was the most
economical system on the market at that time.
Quality & Service
Every unit that Vac-Con produces goes through
its rigorous testing facility. Every unit is raised in
the air and inspectors walk underneath it to check
the wiring and electrical, hydraulics, and
plumbing that is mounted underneath the truck.
Vac-Con inspectors operate every function on
each truck for 2-4 hours. Then the company
repeats the process on the lift again to look for
any issues from the practice run.
“We decided on the Platino
because of its ‘footprint’,
which fit within the
production space of our
building. As we researched
the laser market, we also
discovered that Platino and
the TowerServer was the most
economical system on the
market at that time.”
“Another reason we chose Prima was that in
years past, we’ve had some issues with the
customer support and service support,” says
Graden. “Prima management made a
commitment to us that if we bought the machine
6
Vac-Con is one of the world’s leading manufacturers of sewer cleaning
and excavating equipment, producing such products as combination
sewer cleaners, jetters, and industrial vacuums.Vac-Con manufactures
these products to be sold to municipalities and contractors across North
America, as well as South America, the Middle East, and Europe.
that they would continue to support the system as
long as we had it in our operation. And for the
past three years, every time we’ve needed
assistance, they’ve honored our partnership.” Bill
Barnes, plant engineer /maintenance manager
adds: “We still communicate on a regular basis
with the tech that did the Prima installation in
2007. We have each other’s phone numbers. They
do a good job of supporting me. Whether it is a
quick software calibration fix, parts, or service,
they have always been there for us.”
Most of the products that Vac-Con manufactures are cut
from steel plate – 20 gauge up to 2 1 /2 inches.

FOCUS ON TOOLING
New Options for Forming Efficiency
Prima Finn-Power turret press users now
have additional options for more flexible,
efficient, and affordable forming
operations.
Ultraform Fx And Ultraform
Xt Holders
First up are Mate’s new Ultraform FX and
Ultraform XT holders that offer fabricators the
flexibility of Mate’s top-of-the-line ULTRAFORM®
insert system, yet even more affordable.
Ultraform FX and Ultraform XT both take
full advantage of the interchangeability of
Mate’s ULTRAFORM insert system without all
of the features. The reduced holder complexity
is for machines with precise stroke control, such
as Prima Finn-Power® eMachines. They’re also
for customers who do not want or infrequently
use length adjustment.
Ultraform Fx:
Ultraform FX is a fixed-length holder designed
for customers who:
■ Desire flexibility
■ Own machines with precise stroke control
■ Do not want length adjustment –
Ultraform FX uses Mate’s Ultraform holder
system so that customers may use an
unlimited number of forming tools with
the same holder.
Available in B through E-Stations,
Ultraform FX features multiple angle settings of
0, 90, 180 and 270 degrees and lubrication
grooves.
Ultraform Xt:
Ultraform XT is designed for customers who:
■ Desire flexibility
■ Perform infrequent length adjustment
Ultraform XT uses Mate’s ULTRAFORM
holder system so that customers may use an
unlimited number of forming tools with the
same holder.
Available in B through E-Stations, Ultraform
XT features multiple angle settings of 0, 90, 180
and 270 degrees and lubrication grooves. To
adjust the length, customers just need to loosen
the head cap and turn the punch head.
Eliminate A Secondary Operation
With Rollerball Deburr
The punching process frequently causes burrs
on sheet metal parts. Removing them often
How Rollerball Deburr works:
7
By John Galich, Marketing Manager, Mate Precision Tooling
requires secondary deburring operations that are
either performed manually or use specialized
equipment. With Mate’s new Rollerball Deburr
tool, you may eliminate these costly secondary
operations right at the punch press. Sold as a
set, Rollerball Deburr comes complete with
everything you need, including three springs
that allow them to adjust the tension
appropriate to the material being punched.
Rollerball Deburr is available in Ultraform,
Ultraform FX and Ultraform XT versions.
Mate’s Rollerball Deburr tool takes
advantage of its Rollerball technology, which
uses the extended programming capabilities
presses that can operate in the x and y axis with
the ram down. Rollerball Deburr pushes the
burr away and creates a radius on the side of the
part. Using a special ball in both the upper and
lower part of the tool, every possible part
contour can be processed—even small corners.
Mate Rollerball Deburr can be used with such
materials as mild steel, stainless steel and
aluminum materials.
Mate’s forming solutions gives Prima Finn-
Power users additional opportunities to
maximize the efficiency of your turret press.

BENDING TECHNOLOGY
Discovering the
Best Path to
Better Bending
Analyze the options, from the
stand-alone press brake to the
fully automated panel bender
By Michael Stock
Think about the old days for a second. A
single-station duplicator punch press was
the epitome of blanking precision for
many a contract fabricator. Then this new
technology called a turret punch press came
along. It could hold multiple tools, move the
sheet to the right location, and cut interior
holes and part profiles. Production went
through the roof. Then the laser cutting
machine emerged on the scene and removed
tooling and the associated setup from the
equation, increased part profiling and sheet
nesting flexibility, and yielded higher machine
efficiency and maximum throughput in highmix,
low-volume applications.
However, more important than that, for the
first time the machine controlled part quality. As
long as it had the right program and the correct
punch tools or laser focusing head, a blanking
machine could read and execute programmed
instructions correctly from the first part
onward. If another batch of those parts came in
a week, a month, even a year hence, the
machine could produce the exact same part.
To be sure, skilled personnel are still
needed to program, set up, and maintain the
machine, and periodic edge quality inspection
is still as important as ever. But when it comes
to process operation, a human no longer needs
to monitor a machine continuously to ensure it
makes good parts.
More recently, bending technology has
undergone a similar evolution, but admittedly,
the challenges have been more complex. The
modern press brake is now a CNC machine
capable of high repeatability, but it still requires
an operator to hold the part during the process
and set up the tooling. A multiaxis robot can be
integrated with the CNC brake to eliminate
operator handling, but currently it does not
efficiently address the tooling setup from one
part to the next.
The panel bender changes this. The
bending process can be fully automated—
automatic tool setup, automatic part loading,
complete part manipulation, and unloading (see
Figure 1). It produces positive and negative
bends quickly and accurately, no blank flipping
required. The part stays flat on the machine
table as only the flange is bent. Now, like the
blanking machine, the bending machine controls
FIGURE 1 The level of bending automation you need depends on myriad factors, such as part size and expected volume. In this setup,
an automated blanking and panel bending cell speeds the fabrication of large panels.
part quality and, on some parts, forms in
seconds what would take a press brake a few
minutes.
“Panel benders can’t handle
everything a stand-alone or
robotized press brake can, but
then again, it can do many
profiles that are either very
difficult or impossible to do in
a press brake.”
Note the key phrase, though: some parts.
Panel benders can’t handle everything a standalone
or robotized press brake can, but then
again it can do many profiles that are either very
difficult or impossible to do in a press brake. In
fact, bending automation has always been more
8
complex. Aside from using punch form tools,
blanking deals mainly with just two dimensions.
In bending, you have all three to worry about.
Choosing which bending technology is best
involves balancing maximum throughput with
your expected return on investment. To uncover
that, you need to have a good understanding of
the bending requirements specific to your
application and know exactly how your bending
operators spend their day; that is, how much
time they spend bending versus not bending.
You need to know the setup times your parts
require; downtime between jobs; the percentage
of time operators are handling the part; your
scrap rate, including scrap produced during
setup (tryout parts) and rejected pieces produced
during the run; and your average daily output of
each machine. You need to know your expected
part volume and optimal batch size that
minimizes the cost of work-in-process (WIP).
You also need to keep an open mind to all the
bending options out there—and there are many.

Technology Basics
Press brakes are common for a reason: They’re
inexpensive and versatile. If stage bending, you
can carry a complex part through multiple
bends on different tool sets within one brake
bed, and finish a complex part after just one
handling. If you’re using special tools, such as
an offset punch and die set, and if the brake has
sufficient tonnage, you can bottom-bend a
complex geometry precisely, in one hit.
But the brake has drawbacks that have
given headaches to many a metal manufacturer.
Often the press brake remains the operation’s
principal bottleneck. Why? It’s because of setup
and the high level of operator skill generally
required. It takes time to switch out tools and
create or retrieve an existing program, and it
may take a few tryout pieces to make a good
part. Recent press brake technology has helped
reduce this time via quick-change tool clamps,
multiaxis backgauges, and real-time control
feedback that detects variances in material.
FIGURE 2 A panel bender can perform positive and
negative bends without flipping the workpiece.
FIGURE 3 Behind the panel bender’s hold-down tool
segments, shown at left, are two bending blades. One moves
up for positive bending, the other moves down for negative
bending (blades are shown in the center, at the bottom and
top of the image).
But the basic premise of brake bending has
remained the same for decades. The brake
applies pressure to the blank in three places: the
two die shoulders on the bottom and the punch
tip on the top. To air-bend, the punch descends
a predetermined distance into the V die, below
the die shoulders. Mathematically, you can
determine how far the punch needs to go to
bend a sheet of a certain thickness to the
specified angle. This equation involves not only
the final outside radius desired, but also the
material thickness. So as thickness varies
unexpectedly, the radius changes a little bit,
which influences the actual bend angle—hence
the need for those test parts.
A panel bender is different. The material
isn’t bent with pressure applied on both sides of
the metal. Instead, the sheet is positioned under
a hold-down tool and a flange is bent in the
positive or negative direction. A bottom blade
moves up to bend positively; a top blade moves
down to bend negatively (see Figures 2 and 3).
The upper hold-down tool segments and
stationary bottom hold-down tool clamp the
blank in place, but they don’t directly form the
metal. The only forming pressure applied comes
from those upper or lower blades. The sheet
metal is formed with just one pressure point
from the blade on one side of the sheet—a lot
less complicated than the press brake’s three
points of pressure. The blades approach the
flange in a curved movement (technically
speaking, through interpolation of two axes), so
they maintain a single point of contact
throughout the bend. Without this, the blade
would slide against the flange during bending.
The curved movement also allows for complex
bending operations, like radius bumping,
without specialty tools (see Figure 4).
Panel Bending Advantages
Automated panel benders thrive on large
workpieces with both positive and negative
flanges that are difficult to handle in the press
brake. Also, material variation and springback
can be less significant on a panel bender because
the bending method generally puts less stress on
the workpiece.
Referencing differs in a panel bender.
Before bending, the sheet is placed against
locating pins. The hold-down tools clamp on,
the locating pins move out of the way, and the
upper and lower blades move in to commence
bending, starting with the outermost bend and
moving inward. Because the machine handles
the part during bending, it can reference all
bends from the center of the blank out. This
means bends aren’t referenced off of previous
bends, as they are with a conventional CNC
press brake, with operators holding those prior
bends against the backgauge. It doesn’t matter
how sophisticated a press brake’s backgauge is; if
a previous bend is off, those loose tolerances will
accumulate over subsequent bends.
FIGURE 4 A panel bender’s bending blades move in a curved
motion to perform complex bending operations, including
radius bumping.
9
“Automated panel benders
thrive on large workpieces
with both positive and
negative flanges that are
difficult to handle in the press
brake. Also, material
variation and springback can
be less significant on a panel
bender because the bending
method generally puts less
stress on the workpiece.”
In a panel bender, the angle is determined
not by the tooling, but by the motion of the top
and bottom bending blades. It’s the hold-down
tool segments that must be changed out for
various part widths. Many panel bender models
change out these upper tools automatically,
often within a few seconds (see Figure 5).
An automated panel bender uses a
manipulator to move the blank by sliding it into
the hold-down tools to correctly position the
bend line for the required bend sequence, then
turning it to the next side. Some stand-alone
panel benders remove the table and
manipulator, leaving blank manipulation to a
human operator or articulating-arm robot.
FIGURE 5 On this panel bender, the top hold-down tool
segments are changed out automatically.
Panel Bending Limits
Knowing this, you might wonder why all the
press brakes in the world aren’t replaced by
panel benders. Sure, the panel bender is more
expensive than the press brake, but a panel
bender’s productivity is so much greater. So it’s
not just about the price tag. It’s really because a
panel bender can’t handle everything a press
brake can.
Most benders can’t handle stock thicker
than 11-gauge mild steel. Also, automated panel
benders work with parts that are only so small,
generally a little more than 6 in. wide,
continued on page 10

BENDING TECHNOLOGY
continued from page 9
depending on the exact part dimensions and
bend requirements. Anything smaller and the
manipulator can’t handle the part (see Figure 6).
Stand-alone panel benders don’t have a
manipulator, but parts still must be large
enough to be handled by at least one 4.5-in.wide
hold-down upper tool segment.
Panel benders can form flanges only so high
or long. Typical applications involve flanges 8
in. and less. This is due to the panel bender’s
design. Behind those upper and lower bending
FIGURE 6 On this automated panel bender, a
manipulator moves the blank into position.
blades is a rigid C frame with (you guessed it)
an 8-in. throat. Any flange greater than that
would interfere with the machine.
Some panel benders also can have trouble
with some interior flanges, no matter their
height. Picture a 4-foot-square blank with a
cutout window in the center having a flange on
at least two sides, which need to be bent up.
Remember the panel bender’s 8-in. throat? In
most cases, the sheet can’t be positioned far
enough in to make those bends. And even if it
could, the manipulator common to most
automated panel benders couldn’t hold the part,
because the material is missing in the center.
Similarly, a panel bender has trouble with
blanks with punched forms, such as louvers,
specifically on the negative side of the sheet.
The sheet can’t lie flat anymore, which means it
won’t suit a panel bender.
Such benders also can’t bottom-bend an
offset or some other special form profiles like a
press brake can, and this makes certain precision
bend geometries better-suited for the press
brake, particularly those formed in one hit with
special tools. For instance, some jobs require a
one-metal-thickness offset on the edge of a
panel so it can fit up with an adjacent panel
when assembled. A panel bender can air-bend
this to a lazy offset, which may be suitable, but
it can’t do it with the precision, 90-90-degree
accuracy obtained with the special single-hit
offset tooling in a press brake, provided the
brake has sufficient tonnage.
Avoid Tunnel Vision
Still, such an offset bend could be formed
upstream in a turret punch press using a wheel
tool, then make its way to the panel bender for
the remaining bends. This fact proves an
important point: Avoid tunnel vision when it
comes to bending options. It isn’t just about what
bends a machine can do; it’s about what
combination of technology produces maximum
throughput and quick ROI. A large percentage of
parts usually can be redesigned to maximize the
advantages of this technology.
For automated panel benders, an acceptable
ROI usually requires higher part volume. Note
that “volume” in this sense doesn’t mean large
batch sizes. On the contrary, one of the greatest
advantages of a panel bender is that it can be
programmed to bend short runs of complex parts
with mere seconds of hold-down-tool changeover
time between them. These machines are great at
handling very small batch sizes. The more setup
time an operation takes on a press brake,
generally the more time a panel bender can save.
So in this case, “large volume” may mean a great
number of short-run parts. Call it “high mix,
high volume.”
Of all the bending options, the stand-alone
press brake is the least expensive, followed by the
robotized press brake. A stand-alone panel bender
is generally more expensive (depending on
product configurations), followed by the same
panel bender with an integrated robot. Finally,
there are the fully automated panel benders and
integrated flexible manufacturing systems with
material and part retrieval.
Some might raise their eyebrows at the
stand-alone panel bender: Why is it more
10
“Some might raise their
eyebrows at the stand-alone
panel bender: Why is it
more expensive than the
robotized press brake? Here,
you have to look at
efficiency and productivity,
particularly when it comes
to complex parts.”
expensive than the robotized press brake? Here,
you have to look at efficiency and productivity,
particularly when it comes to complex parts.
Robotized press brakes are great at handling
large, heavy parts that would strain operators.
But if a person spends a lot of time setting up a
press brake for a certain group of short-run jobs,
so will the robot. A robot may be able to move
faster, and it doesn’t go out for a coffee break or
call in sick, but it still must go through all the
motions a human would.
Consider the conundrum many job shops
find themselves in during this economic
recovery. They survive on short-run jobs that
keep money coming in the door, but those jobs
can cause huge headaches on the floor.
Say you have 60 or so orders of 10-piece
runs requiring complex bends and multiple tool
changes on the press brake. With a stand-alone
press brake, you spend most of your time
setting up tools and moving material. And a
robotized press brake doesn’t necessarily make
things easier. Those 60 parts of different
geometries may require about 30 grippers for
the robot—and what robot cell has enough
room for 30 grippers? If you want the robot to
FIGURE 7 In this stand-alone panel bender, the operator positions the part next to the locating pins, and the machine takes it
from there, holding the workpiece during the bending process.

change out tools, you’ll need more grippers, or a
person will need to intervene to perform setups
manually. That makes for a cluttered robot cell
and a lot of extra robot movement, complexity
that may outweigh any increase in part
consistency or reduction in bending cycle time
the robot may achieve.
The stand-alone panel bender, though, is
different. You call up the program (often by just
scanning in a bar code on the job traveler), and
robotic manipulators change out the hold-down
tools. You place the part against the locating
pins, and the machine takes it from there,
completing the operation in a few seconds or
minutes (see Figure 7). If you integrate an
articulating-arm robot within the panel bending
cell, you eliminate the need for human
intervention entirely. A complex part might take
50 seconds on a stand-alone panel bender,
without a robot, while that same part would
take 3 or 4 minutes in a robotized press brake.
This isn’t to say a robotized press brake
can’t be a smart investment. If your batch sizes
generally are 25 or more pieces and parts are of
average complexity, then one skilled brake
technician can operate several automated brake
cells and send productivity sky-high. But just be
aware that a robotized press brake cell isn’t the
only option to increase efficiency, improve part
quality, or automate the bending operation.
Equipment Choice: Where to Begin
A shop with three press brakes that bend 50,000
pieces a year isn’t going to be able to justify an
automated panel bender. Such a machine would
bend parts quickly and then sit idle most of the
time. Yes, as any lean manufacturing guru will
tell you, machine idle time isn’t a bad thing;
overall manufacturing time is what really
matters. All the same, 50,000 pieces can bring
in only so much annual revenue. If such a shop
isn’t expecting to increase sales significantly, it
would take a long, long time to recoup the
investment.
A good candidate for automated panel
bending is a shop with four or more press
brakes processing roughly 100,000 parts or
more a year. This “minimum volume” number
is for the ROI calculation. The more volume
you have (again, this could be a great number of
extremely short-run parts), the faster ROI you’ll
get. An automated panel bender running over
two shifts can produce roughly 350,000 pieces a
year. Obviously, such machines give a shop
tremendous capacity.
A shop with a dozen or so press brakes
might run as many as a few thousand part
geometries over one year. An automated panel
bender may be able to handle only 30 to 40
percent of those parts. But if that percentage
consists of large volumes, or if those parts require
long setup times and are difficult to handle, a
panel bender would produce a quick ROI. It
would increase part consistency and, because
setups happen in seconds, allow the
shop to run even smaller batch sizes to
reduce the cost of WIP.
But what if that 30 to 40 percent
doesn’t entail a large enough volume
of total parts? Here the automated
panel bender might not be the best
solution. In this case, a stand-alone
panel bender that does not have a
manipulator might suit, because it can
handle a greater variety of blank
sizes—perhaps enough to handle 60
to 70 percent of your part mix. Also,
like with the automated panel bender,
the stand-alone panel bender can send
setup and cycle times plummeting. A
shop with four press brakes needing to
increase capacity may consider adding
two more. But the stand-alone panel
bender alone might be able to do the
work of four press brakes. This means
the shop could invest in the bender
and actually sell two of its existing press
brakes—and still increase capacity while
reducing WIP.
But what if even the stand-alone
panel bender can’t handle that many parts?
What if a shop runs a variety of sheet
thicknesses, with only 30 percent of the part
mix being 11-ga. or thinner? Or perhaps it deals
with a large portion of parts requiring flange
lengths longer than 8 in., and they happen to be
awkward for a person to handle, but still easily
stackable or otherwise manipulated. In these
cases, a robotized press brake might suit best.
In fact, an articulating-arm robot, in a press
brake cell or tied to a stand-alone panel bender,
has its own advantages. Once it’s finished
bending, that same robot can send the bent part
to downstream operations. Want to put the part
on a conveyor to send it to a downstream cell
for hardware insertion? An articulating-arm
robot can do that. How about placing a bent
piece in a welding fixture? A robot can do that
too. In fact, the robot creates a palette of
possibilities that other forms of automation
don’t offer.
Growing With Automation
The level of automation you choose and how
quickly you achieve an ROI depend on the
number of parts that flow through the shop. As
that volume grows, so generally does the level of
automation.
For many, it happens incrementally. A shop
first invests in a level of bending automation
that gives a suitable ROI for their projected
part volume. That piece of automation
increases the shop capacity and shortens leadtimes,
making the whole operation more
competitive. Part volumes grow. The volume
may come from a large number of short-run
jobs, but again, panel benders can handle those
small lots quickly and easily.
11
FIGURE 8 A flexible manufacturing system integrates punching, cutting,
bending, and a material storage and retrieval system. All are coordinated
for optimal line balancing, so that parts arrive at downstream processes at
the right time.
As volume grows further, the shop invests
in more automation, perhaps a flexible
manufacturing system (FMS) that can retrieve
cut parts from the blanking machine, store
them, and then send them on to the bending
cell a few minutes or hours later. The FMS is
carefully timed for optimal line balancing so
that all components arrive at downstream
processes at the right time (see Figure 8).
The right automation adds capacity
without adding more people, increasing the
value of each skilled employee. Skilled press
brake technicians, those who really know the
fundamentals of sheet metal bending, remain
incredibly valuable assets, and they are difficult
to find even during these challenging economic
times. One technician, who perhaps once spent
his or her day standing by one press brake
bending parts, can become much more valuable
operating two or three automated cells
simultaneously.
Michael Stock is manager of bending products for
Prima Finn-Power North America.
Reprinted with permission from THE FABRICATOR.
July, 2010

EUROBLECH TRADE SHOW
“Green Means” From
Prima Finn-Power
Under the theme – “Green Means” – Prima
Finn-Power’s EuroBLECH booth was the
center of intense interest from fabricators
throughout Europe and the world. Not only were
the throngs of visitors enthusiastic, but
demonstrated strong signs of a resurgence in the
economy. Prima Finn-Power sold a record amount
of equipment during EuroBLECH 2010.
“Over the years, both the Prima and Finn-
Power product lines have been developed towards
greater flexibility and operating economy through
versatility, high automation level, and low energy
and maintenance cost,” says Tomas Hedenborg,
SVP in charge of sales, service, and marketing.
“Also for a long time, the ecological aspects have
been included among design criteria. It is now
time to sum up all the eco-friendly freatures and
tell the fabricating world that we can truly provide
them with Green Means. This translates into
technology and knowhow which will meet the
requirements of both productivity and more
sustainable manufacturing.”
The Prima Finn-Power list of equipment at
EuroBLECH included:
■ New generation of the Prima Rapido laser
■ Prima Zaphiro 2D high-range laser
■ New servo-electric Shear Genius
■ Flexible Fast Bend servo-electric bending
machine
■ New version of Tulus software
■ New generation NC Express CAD/CAM
software
12

FABTECH TRADE SHOW
Prima Finn-Power Green Means Makes an
Impact in Atlanta
The Prima Finn-Power booth was filled with curious fabricators from the
Southeast and across the country in the Georgia World Congress in
Atlanta, November 2 - 4. The FABTECH booth featured the same Green
Means theme as EuroBLECH. Each day of the show, hundreds of interested
visitors entered the Prima Finn-Power booth to see the latest in laser cutting,
bending, and punching technology, including:
■ Fast Bend, a new servo-electric bending concept, capable of bending five
different parts in just five minutes
■ Zaphiro, a new high-range 2D laser
■ E5x, the cost efficient, servo-electric punching center
13

CUSTOMER PROFILE
Pulverman Thrives with Prima Laser Systems
Pulverman Precision Metal Components,
Dallas, PA, was founded in the 1940's as
a machine/fabrication shop that
primarily serviced the local industry's machine
and HVAC requirements. Randy Mark,
president, purchased Pulverman in September,
1999. At that time, the company had only eight
employees, a small 9,600-square-foot
production facility, and sales revenues below
$500,000 per year. However, with this
acquisition, Pulverman’s financial future was
about to change dramatically.
Mark transformed the company into a
contract manufacturer servicing such diverse
industries as trucking and transportation,
HVAC, medical cabinetry, construction,
computer doors, industrial components,
appliance, food processing, agriculture, among
others. In 2004, the company moved into its
new 80,000-square-foot facility with over 160
employees. And sales revenues have soared to in
excess of $20-million per year.
Company Growth & Engineering
“Through our emphasis on contract
manufacturing and diversity, we’ve been able to
grow our business,” explains Mark. “We’ve
experienced double digit growth every year
except in 2009. We have evolved into a multimillion
dollar company that provides our
customers with laser cutting, fabricating,
machining, stamping, and powder coating
capabilities. Our highly trained and experienced
engineering group provide our customers with
technical expertise, product improvement ideas,
and new product development support.
Through our product improvement strategy, we
can offer design alternatives for parts and
assemblies to improve or reduce cost of an
existing configuration. Our modern software
tools – including AutoCAD and 3-D modeling
– give us the opportunity to share information
According to Ken Yermal, engineer, while lights out automation is not a major part of Pulverman’s current production, the Prima
Platino lasers have helped the company trim labor costs. With two people, the company is able to run all three Platino lasers
efficiently, and have parts that are already out of the skeleton and ready to move to the next operation. In most cases, no deburring
operations are needed.
In order to expand its laser cutting capabilities, Pulverman purchased a Prima Platino 2D laser system with a 10-shelf TowerServer in
2004. The Platino is equipped with lasers developed and produced at Prima Industrie in laser powers ranging from 3000 to 5000W.
The laser cuts a broad range of materials and thicknesses with speed and precision without the need for manual adjustments.
14
“The Prima Platino lasers run
three shifts a day, five days a
week – and partial shift on
weekends. Considering what
we do to them, they hold up
very well.”
electronically in a way that is beneficial to our
customers. We also offer computermanufacturing
systems for our customers and
we are EDI and capacity planning capable.”
Prima Platino Lasers
In order to expand its laser cutting capabilities,
Pulverman purchased a Prima Platino 2D laser
system with a 10-shelf TowerServer in 2004.
The Platino is equipped with lasers developed
and produced at Prima Industrie in laser powers
ranging from 3000 to 5000W. The laser cuts a
broad range of materials and thicknesses with
speed and precision without the need for
manual adjustments.
Platino’s laser cutting head gives users a
choice of a 10-inch focal length in addition to
the standard 5-inch and 7.5-inch lenses. The 10inch
lens enhances the application flexibility by

“We are very impressed with
the Prima lasers and the
company’s service. Back in
2004, I never imagined
having three Prima lasers
when we bought the first.
Today, I don’t believe we
would ever buy a different
brand. We are quite satisfied.
From a service standpoint,
there is a high level of
responsiveness and a very
good relationship that is very
important to us. The
interaction is there. We also
run our machines very hard,
as evidenced in our first
Platino, which has over
46,000 hours of run time.”
increasing the depth of focus and enlarging the
spot diameter for high and uniform cut quality
of thick stainless (5/8 inch), thick aluminum
(1/2 inch) and thick mild steel (1 inch).
Offering a compact footprint along with a
Cartesian, Cantilever structure that provides
three-sided access, Platino is a cost-effective
machine that is easy to operate and quick to
program. Its unique stonecast frame reduces
vibration and increases stiffness by about 4
times compared to cast iron and about 6 times
compared to welded frames. Its low heat
conductivity results in much higher thermal
stability compared to traditional cast or steel
frames.
TowerServer
Prima’s 10-shelf TowerServer allows easy
loading/unloading for blanks and processed
sheets. It has an elevator for loading and
unloading the pallets on and off the tower, and
features single sheet separating, control systems,
and sheet reference. “We tend to run medium
thickness, longer-running parts on the 4000W
Platino laser with the TowerServe,” explains Ken
Yermal, engineer. “We run the parts that repeat
through the shop every single week.”
In 2006, Pulverman purchased a second
Platino laser with a load/unload. “We really like
the flexibility of the load/unload,” says Yermal.
“It gives us the ease of loading and unloading
sheets, just like we do on the large tower. All we
have to do is touch a few buttons to unload a
scrap sheet and load a new sheet. With the
load/unload, we can just load the material that
we are running at that moment.”
Pulverman purchased a stand alone Platino
4000W laser in 2008. “We run our heavy plate
on this machine,” explains Yermal. “It is used
for long running jobs that are the same heavy
material.”
The latest Platino laser, also 4000W, was
installed in January 2010. It replaced the
original Prima laser that is used with the
TowerServer.
Workhorses
According to Yermal, nearly 50% of all the
product Pulverman produces goes through the
Platino lasers. “A lot of our lighter material and
parts that are not very intricate tend to go
through the turrets, and anything that is
heavier, has intricate contours, and takes more
time to process ends up on the lasers,” explains
Yermal. “The Prima Platino lasers run three
shifts a day, five days a week – and partial shift
on weekends. Considering what we do to them,
they hold up very well.”
“We are very impressed with the Prima
lasers and the company’s service,” adds Randy
Mark, president. “Back in 2004, I never
15
Prima’s 10-shelf TowerServer allows easy loading/unloading
for blanks and processed sheets. It has an elevator for loading
and unloading the pallets on and off the tower, and features
single sheet separating, control systems, and sheet reference.
imagined having three Prima lasers when we
bought the first. Today, I don’t believe we would
ever buy a different brand. We are quite
satisfied. From a service standpoint, there is a
high level of responsiveness and a very good
In 2006, Pulverman purchased a second Platino laser with a load/unload. According to Yermal, the flexibility of the
load/unload gives Pulverman the ease of loading and unloading sheets, just like on the large tower. All the operator needs to
do is touch a few buttons to unload a scrap sheet and load a new sheet. With the load/unload, the company can just load the
material that it is running at that moment.
continued on page 16

continued from page 15
relationship that is very important to us. The
interaction is there. We also run our machines
very hard, as evidenced in our first Platino,
which has over 46,000 hours of run time.”
“When we purchased the first Prima laser,
we experienced very good results from the
machine,” says Yermal. “We also experienced a
long run of reliability. If there were any
“When we purchased the first
Prima laser, we experienced
very good results from the
machine.We also experienced
a long run of reliability. If
there were any problems with
the machine, the service was
very reliable…and a tech
arrived here the same day or
the next day.”
problems with the machine, the service was very
reliable…and a tech arrived here the same day
or the next day. We were never down for a long
period of time, and we developed a very good
working relationship with Prima. In addition,
on several occasions, Prima offered to train our
operators in how to take a look at our cut
quality and identify what the problems are and
what parameters need to
be adjusted. When we
employ new operators or
start to cut new material,
I give a call to Prima and
they have been very
helpful.”
Labor Savings
While lights out
automation is not a
major part of Pulverman’s
current production, the
Prima Platino lasers have
helped the company trim
labor costs. “Each shift,
we have one operator and
one helper running three
machines,” explains
Yermal. “The skilled
operator is responsible for
anything that needs to be
done on the machine, such
as beam alignment, and he
oversees what is being run on the machine, lines
up what jobs are next, etc. His helper will pull
the parts off, unload the skeleton, get the next
sheet ready for processing, etc. With two
people, we are able to run all three Platino lasers
efficiently, and have parts that are already out of
the skeleton and ready to move to the next
operation. In most cases, the cut quality is
running good, and we don’t need to perform
deburring operations…the parts move directly
to the press brakes.”
The latest Platino laser, also 4000W, was installed in January 2010. It replaced the original Prima laser.
16
Nearly 50% of all the product Pulverman produces goes through the Platino lasers. The
Prima Platino lasers run three shifts a day, five days a week – and partial shift on
weekends.
Expansion
Pulverman is currently adding a 3,000 squarefoot
office expansion to its facility to
consolidate offices and to better centralize
departments. “We are creating a better office
environment for our entire management group
– production, engineering, purchasing, and
sales – that will help us operate more efficiently.
Plans to add 3,000 square feet of additional
manufacturing space in later 2011 are also in
the works,” concludes Mark.
“We really like the flexibility
of the load/unload. It gives us
the ease of loading and
unloading sheets, just like we
do on the large tower. All we
have to do is touch a few
buttons to unload a scrap
sheet and load a new sheet.
With the load/unload, we can
just load the material that we
are running at that moment.”

FOCUS ON TOOLING By David Bishop, Business Development Manager, Wila USA
CATCH THE WILA ® WAVE
Finished Part Perfection With No Die Shimming
It is common for die shimming to account for up to fifty percent of setup
time on an average press brake that is eight feet (2.5 meters) in
length or longer. Tooling wear, along with the deflection that naturally
occurs on press brakes of this length and longer must be compensated for,
or long parts will often come out looking like a canoe. Failure to address
this issue can also make things difficult in the assembly area and in the
field where parts are mated to other assemblies.
To make matters worse, shimming dies on a press brake is a skill that
can only be learned with a lot of time and experience running a press
brake. No one can teach you how to accurately shim press brake dies for
whatever material lengths and material types that may come in the door,
and there are no manuals available to tell you which shims to use and
where to place them. And needless to say, picking up and setting down
long heavy dies repeatedly in order to shim them properly is an unsafe and
often dangerous practice. It is for these reasons that Wila produces the
world’s most advanced crowning systems.
Advanced features include:
■ Patented Wila Wave® technology provides perfectly smooth and
consistent bend angles over the full length of each part
■ Centralized adjustment, making them simple and extremely fast to
set-up
■ Localized adjustments every 8” (200 mm) to compensate for machine
and tooling wear along the full length of the machine
■ Available with a CNC motor that is integrated with the machine’s
control to automatically set the proper crown position prior to each
bend
■ Most manually driven models include a hand crank with digital
readout, making it fast and easy to repeat set-ups
■ Available with hydraulically driven clamping pins for ultra-fast set-ups
■ Can accept any type of die from Single-V Dies, 2V Dies, Wila Multi-
V Dies, Channel Dies, and 4-Way Dies
■ Available in special widths up to 24” (610 mm) to accommodate press
brakes with wide beds, applications involving heavy plate forming,
and dies with extra large V-openings
■ Can be used with tandem press brakes
■ Available in lengths of up to sixty feet (20 meters)
■ Models available to meet every budget
17
.
It doesn’t matter which press
brake you own, how long it is,
how much tonnage it can apply,
or what you are using it to
produce, Wila has a crowning
system that is perfectly matched
for your press brake, your
bending requirements, and your
budget. More fabricators choose
Wila Crowning Systems each year
than all others combined. Catch
the Wila Wave and eliminate
costly die shimming, while
enjoying finished part perfection
and maximum productivity.

SOFTWARE UPDATES
Tulus Machine Software
Tulus is Prima Finn-Power’s integrated and scalable software tool for
centralized management of fabrication from a single machine to a
factory wide process. Tulus controls machines by tasks and provides
an easy way of adding new production orders to the task list.
Fast production change requests and utilization optimization are now
easy to handle simultaneously.
Tulus productivity enhancement features:
■ Online process simulation view
■ Tool data synchronization with NC Express
■ Easy tool setup with automatic optimization
■ Restart from simulation screen
■ Automatic stacking management
■ Visualized online machine status, axis coordinates, inputs etc. for
easier diagnosis
■ Improved touch screen support
Optional features:
■ Swift tool setup: scan coded tool for quick setup
■ Tulus office: utilize features offline from machine
■ Tulus reporting: machine performance and utilization
Tooling/turret – Tool setup is fast due to graphical turret view and
online tool data synchronization with NC Express.
Task list/simulation – Tulus is easy to use. Online task list helps speed
up the setup processes, and online simulation shows process status clearly.
18
by Kyle Plass, Applications
Laser – Laser setup is fast with integrated laser technologies &
parameters and visualization of the cutting process.
Stacking management – Tulus is a powerful tool for automatic production
with features such as automatic online stacking management, visualized
information on stacking and sorting, as well as online production follow-up.
Easy to use – All functions now within one software; easy to use interface,
machine functions are simple to control via graphics on screen.

NC Express Programming Software
The advances of computer technology continually allow the ability for
better processes to be developed within software. Prima Finn-Power
has realized this and has made new developments and many
enhancements to the control and programming software for all Prima
Finn-Power equipment.
NC Express is a production management tool designed to provide
maximum positive impact on manufacturing flexibility and
efficiency for Prima Finn-Power equipment.
Main NC Express features included:
■ Windows user interface
■ Orders Management System (MRP/ERP connectivity)
■ Geometry importing and editing
■ Automatic feature based tooling
■ Automatic true shape random part nester
■ Fully automatic machine optimization
■ Automatic clamp settings to minimize dead zones
■ Index & Multi-Tool optimizations
■ Laser DPM+ high speed cutting
+ Easy Windows user interface & common functions
+ CAD functions, 2D import, 3D unfolding (optional)
= Easy To Use
19
Additional features:
■ Unfolder to open 3D models
■ Parametric programming for JIT production
■ Automatic batch processing and ERP
+ Full setup and production reporting for operators and management
+ Automatic machine sequence optimization for punch, shear, and laser
+ Full system simulation for error checking and reliable production
= Highest Machine Productivity
+ Efficient automatic nesting of punching, shearing & laser
+ Automatic part sorting and stacking for automated system
= Material Savings & Automation

CUSTOMER PROFILE
Emerson Discovers Flexible & Lean Manufacturing
with Finn-Power Equipment
Emerson Network Power’s Liebert business
is a leading supplier of data center
infrastructure solutions including
precision air conditioning, critical power, and
infrastructure monitoring systems. Its primary
market is data centers that need to maintain
precise temperatures for reliable IT equipment
performance. Liebert HVAC and system cooling
solutions protect mission-critical applications
from variations in temperature and humidity,
ensuring business continuity for Emerson
customers.
In 1997, manufacturing managers at the
Liebert Precision Cooling facility in Columbus,
Ohio decided to replace their existing legacy
mechanical turret punch presses. Instead of
merely replacing the mechanical machines with
hydraulic models, the company invested in
Shear Genius flexible manufacturing cells from
Finn-Power.
Shear Genius flexibility
With the Shear Genius integrated punch/right
angle shear combination concept, the objective
is to provide one machine capable of
transforming a full-sized sheet into punched
parts. These parts can be moved to secondary
operations utilizing the sorting and stacking
automation and on to bending operations
without being touched by human hands. As
loading, punching, and shearing of parts
become automated, the result is finished parts
with a dramatic reduction in scrap and manual
labor while increasing profitability.
With the Shear Genius integrated punch/right angle shear combination
concept, the objective is to provide one machine capable of transforming a
full-sized sheet into punched parts.
The Shear Genius functions with
sophisticated simplicity, able to perform the
most demanding jobs with minimal set-up times
and "lights out" operation. The Shear Genius
increases material productivity through efficient
The EBe servo electric Express Bender is a bending solution that is designed specifically for each fabricator’s production
requirements to achieve maximum productivity, quality, and repeatability. The bending operation is fully automated, from
the loading of flat punched parts to unloading of the finished product.
and versatile nesting programs. The level of
automation can be customized through Finn-
Power's flexible modular solutions for raw
material storage, loading, unloading, sorting and
stacking. These features can be added
later as budgets allow and production
demands increase.
The Shear Genius eliminates
wasteful skeletons and costly
secondary operations such as
deburring. Nibbled edges on the part
exteriors are eliminated through the
use of the integrated right angle
shear. In fact, the same clamps that
hold the sheet for punching also hold
it for shearing. In essence, the Shear
Genius allows the automated process
to begin with a full-sized sheet of
material and end with a punched
part after automated loading,
punching, forming, shearing,
stacking and unloading – all in one
operation. This allows true singlepiece
flow to be synchronized with a
customer’s takt time.
According to Jack Somerville,
manufacturing engineering manager at the
Emerson Columbus Ohio facility, the Finn-
Power Shear Genius has made its mark at
Emerson. “The integrated shear is a feature that
20
originally sold us on the Shear Genius,” explains
Somerville. “Other features we really like
include the large turret with a Multi-Tool, the
automatic sheet feeder for raw stock, the
“The decision to purchase this
cell was the result of the
reliability we had experienced
from the Shear Genius
equipment since 1997. We
wanted to achieve continuous
part flow from the Shear
Genius to the EBe bender.”
conveyance system to dispose of scrap, and the
machine’s overall robustness and durability.
There is a lot of uptime with the Shear Genius.”
Through the years, the Emerson
Columbus, OH facility has added new
generations of Shear Genius equipment to its
fabrication arsenal. Today, it has a total of five
Shear Genius cells and one Laser Punch cell.
Based on its success, other Emerson plants have
added the Shear Genius (SG) to their machine

equipment lists, including:
■ Delaware, OH – two SGs
■ Ironton, OH – five SGs
■ Mexicali, Mexico – five SGs
■ Reynosa, Mexico – six SGs
Punch/Shear/Bend/Weld Cell
Supporting management’s commitment to lean
manufacturing, Emerson Network Power
purchased an automated cell from Finn-Power
in the spring of 2008. The cell includes the
Shear Genius, a picking/stacking robot, and the
EBe automated bender.
The EBe servo electric Express Bender is a
bending solution that is designed specifically for
each fabricator’s production requirements to
achieve maximum productivity, quality, and
repeatability. The bending operation is fully
automated, from the loading of flat punched
parts to unloading of the finished product.
The EBe bender has a maximum bending
length of 100.39” (2550 mm) and a maximum
“There is a savings of 30% in
labor when running the EBe
over the manual brake.”
opening height of 8” (200 mm). The new
construction features actuations of the bending
blade movements (vertical and horizontal) by
NC servo axes instead of hydraulic cylinders.
The upper tool movements are also made by
another NC servo axis.
Finn-Power EBe provides the high bending
quality required in demanding applications.
The quality is achieved through precise control
of bending axes, fast and smooth bending
motion, open programmability, and rigid
construction that is immune to variation in
thermal conditions.
Jack Somerville, manufacturing engineering manager (right) and Fred Crumb, production
line manager, inspect a part formed on the EBe. The EBe has increased Emerson’s precision
and reduced variation, cutting the company’s weld time in half.
“The decision to purchase this cell was the
result of the reliability we had experienced from
the Shear Genius equipment since 1997,”
explains Somerville. “We wanted to achieve
continuous part flow from the Shear Genius to
the EBe bender. Finn-Power offered the
seamless communications and parts handling
required to flow parts from the Shear Genius to
the picking/stacking robot (PSR), and through
to the EBe. The high quality and all electric
features of the EBe were very impressive. Two
years ago, not all manufacturers had electric
benders that were that flexible and had as good
of a tool changeover method. With its
automatic tool change, the EBe has the ability
to run any part, any time, with very quick
changeover. This feature was key for us. It
allowed us to achieve our lean objective of
flowing parts through the cell as well as
providing the flexibility of running several part
numbers at the same time.”
Three SGs feed material to the EBe, which
runs three shifts during the week. “The EBe cell
runs 20% of our volume in the department,”
adds Fred Crumb, production line manager.
“We installed the cell in May 2008 and made
production level quantities in August. It has
reduced our setup times dramatically compared
to the 18 minute changeover from our press
brakes. Some tool changes on the EBe are done
manually, yet only take about 3 minutes;
however, 80-90% of the tool changes on the
EBe are done automatically, and those average
only 20-30 seconds. There is a savings of 30%
in labor when running the EBe over the manual
brake.”
“Many of our panels are so large that we
needed to have two operators on one press
brake. We now run these parts through the EBe
because only one operator is required. That
operator never has to lift the part to bend it. In
terms of volume, we can now make a panel
every 40-50 seconds.
We make
approximately 300
parts per shift, running
three shifts during the
week. To date, our cost
savings with the EBe
has totaled over
$750,000, consisting
mostly of labor savings
and setup time
reduction.”
21
Custom
modification
Finn-Power also
worked with Emerson
on designing a
conveyor from the EBe
to the next operation,
welding. “During the
runoff in Italy for the
EBe, we asked Finn-Power to make a custom
modification to the unloader,” explains
Somerville. “We needed the ability to flow our
parts in a lean way and did not want to batch
between the EBe and the welder. We wanted to
do one-piece flow because the majority of our
parts get welded with either a TIG or a spot
welding process. In order to help us stay lean
“In terms of volume, we can
now make a panel every 40-50
seconds. We make approximately
300 parts per shift, running
three shifts during the week. To
date, our cost savings with the
EBe has totaled over $750,000,
consisting mostly of labor savings
and setup time reduction.”
and run one-piece flow, Finn-Power modified
the logic in the PLC and modified the unloader
rails so the parts have two ways to exit. They
can exit directly out of the machine down a
conveyor to the welder or they can exit at a 90
degree angle for unloading. As a result, a part
now flows from raw stock through punching,
bending, and welding in six minutes compared
to the two hours it took before we installed the
cell. Finn-Power helped us achieve our goal of
high quality, on-time delivery, and lean
manufacturing.”
High precision
Emerson is also impressed with the high
precision of the EBe. “The EBe has increased
our precision and reduced variation, cutting our
weld time in half,” says Somerville. “Our typical
tolerance is +/- 0.030”, however the EBe easily
gives us +/- 0.010”. This increased capability
has shown up in our welding. We weld the
“Without the Finn-Power
equipment, we would not be
able to achieve the level of
precision and still remain cost
competitive in the market
today. Finn-Power helps us
meet our customer’s
expectations for world-class
products.”
continued on page 22

continued from page 21
corners of our panels, but our product line is more than just panels
with square corners. Approximately half of our panels have a “chiseled”
look with 45 degree angles at the corner. It is unique to our product
and gives our DS product line its personality. Welding these corners
requires a higher level of precision than we could get day-to-day from
the manual press brakes. Before the EBe, the welders had to spend time
Through the years, the Emerson Columbus, OH facility has added new generations of
Shear Genius equipment to its fabrication arsenal. Today, it has a total of five Shear
Genius cells and one Laser Punch cell.
adjusting the corners prior to making their weld. With the EBe, the
corners are much more precise, eliminating the adjustment time and
allowing the welders to work more efficiently.”
According to Somerville, flexible Finn-Power
SG and EBe cell equipment has provided the
following benefits to Emerson’s Liebert business:
■ Improved quality – reduced defects
■ Reduced overproduction with one-piece flow
■ Eliminated fork lift moves between the punch
and the brake operations
■ Improved ergonomics by reducing the
amount of manual loading, unloading, and
flipping of parts
■ Reduced changeover times
■ Reduced the need for two-man jobs at the
press brake
■ Increased efficiency by running the Shear
Genius, EBe, TIG welder and Spot welder
with only three operators
■ Reduced the amount of inventory
■ Greatly improved on-time delivery
“Our products are combination air conditioning
and humidifying units,” concludes Somerville.
“They are more highly engineered than your
average air conditioner sitting on a roof. Our
products go into multi-million dollar computer
centers throughout the world. Our customers
demand units that are highly precise and have
high quality components…with no leaks…no
water on the floor. The quality of the sheet metal
components is just as vital as the quality of any
other component. Without the Finn-Power
equipment, we would not be able to achieve the
level of precision and still remain cost competitive
in the market today. Finn-Power helps us meet
our customer’s expectations for world-class
products.”
Lean Modification / Behavioral Tool
Emerson Network Power’s Liebert business and Finn-Power worked together to connect
Emerson’s machine monitoring system to the new automated cell. The system communicates
from the machine’s PLC to Emerson’s monitoring computer. It tracks accurate runtime,
downtime, and piece count data from both the Shear Genius and the EBe. Emerson
management decided to place 40” LCD monitors overhead each machine so the operators
could also view the machine’s performance real-time. Once the monitors were in place, the
operators began using the real-time feedback to drive up the run-time. They intensified their
efforts to reduce their changeover times so they could keep the machines running. The
production numbers started rising instantly resulting in a 10-15% improvement in run-time.
According to Jack Somerville, Finn-Power’s willingness to customize its PLC outputs was a
critical part of the project. “Finn-Power put one of its most proficient technicians on this
project,” explains Somerville. “He worked as a team with our programmer to develop the right
output signals between the PLC and our computers. We now know when the machine is
running, when it is
blocked, or when it
is waiting for the
next part. This
information goes to
our database and it
is reviewed by
management on a
daily, weekly, and
monthly basis.”
22
Finn-Power worked with Emerson on designing a conveyor from the EBe to the next
operation, welding. The company wanted to do one-piece flow because the majority of its parts
get welded with either a TIG or a spot welding process. Finn-Power modified the logic in the
PLC and modified the unloader rails so the parts have two ways to exit: Directly out of the
machine down a conveyor to the welder or they can exit at a 90 degree angle for unloading.

FOCUS ON TOOLING
Improve Punch Press
Productivity with Specialty Tools
Specialty tools push the limits of what is
possible on the punch press. They
simplify certain operations, making
parts faster and cheaper to produce. They
eliminate secondary operations, reducing part
handling. Wilson Tool offers a variety of
innovative specialty tooling solutions that are
designed to improve productivity and deliver
high-quality results punch after punch.
Drawing in a Turret
The Wilson Multi-Scribe® sheet marking tool
makes it possible to do so much more than
scribing in your turret – from creating simple
logos to drawing intricate designs. This
remarkable tool utilizes interchangeable inserts,
long-lasting diamond tipped inserts for scribing
and a carbide insert when dot-matrix marking
on a wide range of materials.
The Wilson Multi-Scribe comes with 120°
and 150° scribing diamond inserts and 90°
carbide dot-matrix insert. The tooling’s unique
design allows for consistent mark depth even
when surface variations occur. Variable scribe
depth ensures the accuracy of marks from logos
to serial numbers. And Multi-Scribe won’t
deform the material or mark the underside of
the sheet. Multi-Scribe users are limited only by
their imagination.
Create Hinges in One Hit, with
One Tool
Creating strong, functional hinges doesn’t need
to be a cumbersome, time-consuming process.
Fabricating a typical piano hinge requires many
hits using two tools for each knuckle. With the
One-Hit Hinge tool from Wilson Tool, punch
press fabricators are able to produce three
knuckles per stroke using a single tool. Because
only one hit is required, programming is faster
and easier and running costs are reduced by as
much as two-thirds.
The One-Hit Hinge tool produces half of a
knuckle, which when you marry the knuckles
and slide a pin through creates a complete
functioning hinge. The tool is most effective in
odd increments. Fabricators can choose from a
wide variety of pin diameters and material types.
Bend on the Punch Press
No need to move those parts to the press brake.
Wilson Tool’s new Opti-Bend tooling allows
sheet metal fabricators to perform 90-degree
bends, after springback, in a variety of punch
press designs. Performing these bends on a
punch press helps fabricators to reduce or
eliminate the number of secondary forming
operations they may otherwise need to perform
on a press brake.
Opti-Bend tooling creates a 90-degree wipe up
form using a rotating cam built into the die that
acts much like a press brake. The result is little to
no sheet marking and fewer hits are required than
a traditional wipe up tool. Opti-Bend tooling is
available in single hit and progressive styles.
By enabling smaller bending operations on
the punch press, Opti-Bend tooling can
significantly reduce part handling and setup
time resulting in greater productivity.
23
By Jeff Paulson, Marketing Manager, Wilson Tool International
A Tool for Every Application
Whether you have an unusual application
requiring a unique tooling solution, or are
simply looking for a way to produce parts faster
and cheaper, specialty tooling from Wilson Tool
can help. In addition to the solutions described
here, we offer a wide variety of specialty tools
for dedicated punching applications that offer
the same innovation, durability and
performance our customers have come to expect
from all Wilson Tool punch press tooling
systems. Contact your Wilson Tool sales
engineer and let us find the right specialty
tooling for you.

FINN-POWER GROUP
P.O. Box 38
FIN-62201 Kauhava
FINLAND
Tel. + 358 6 428 2111
Fax + 358 6 428 2244
www.finn-power.com
PRIMA INDUSTRIE S.p.A
Via Antonelli, 32
10097 Collegno (To)
ITALY
Tel. +39 011 4103 1
Fax. +39 011 411 28 27
www.primaindustrie.com
PRIMA FINN-POWER
NORTH AMERICA, INC.
555 W. Algonquin Road
Arlington Heights, IL 60005
U.S.A.
Tel. +1 847 952 6500
Fax. +1 847 952 6530
www.finnpower.com
ThePUNCH
TheLASER
TheBEND
TheCOMBI
TheSYSTEM
PRIMA FINN-POWER
NORTH AMERICA, INC.
711, East Main Street
Chicopee, MA 01020
U.S.A.
Tel. +1 413 598 5200
Fax. +1 413 598 5201
www.prima-na.com
TheSOFTWARE
TheTREE
Happy Holidays
from everyone at
Prima Finn-Power!