May 2011 - Amtil

may11 

AUSTRALIAN 

MANUFACTURING 

TECHNOLOGY 

Melbourne 

gears up for 

austech ’11 

Australian Manufacturing Technology May 2011 1 

INDUSTRY UPDATE > MOTORS & DRIVES > CNC CONTROLLERS >CUTTING TOOLS > COMPRESSORS

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Australian Manufacturing Technology May 2011 

www.iscar.com.au 

3

Be one of the first to see what’s new in 

Advanced Manufacturing 

Connect with large numbers of key industry 

contacts in one place 

Learn about the latest products and services 

designed to help grow your business 

Combining with National Manufacturing Week and ausplas 

for australia’s largest ever manufacturing industry event 

Find out more, and register to visit at 

austechexpo.com.au 

oNliNe Media paRtNeR 

Media paRtNeR 

austRaliaN 

MaNuFaCtuRiNg 

teCHNologY 


Austech 2011 

australia’s premier advanced Manufacturing 

& Machine tool exhibition 

24th – 27th May 2011 

Melbourne Convention & exhibition Centre 

south Wharf, Melbourne 

suppoRtiNg paRtNeRs & spoNsoRs 

RN8919 


5

CONTENTS 

Volume 11 Number 4 May 2011 

ISSN 1832-6080 

Editorial 8 

INDUSTRY NEWS 

Time for a new approach to workplace training 11 

Carbon price talk puts solar on front burner 12 

Walter expands range with Smartphone app 14 

State govt.. welcomes WA’s newest wind farm 16 

Trade review provides renewed focus on trade 17 

Green manufacturing takes aim 20 

GM Holden vindicates new car plan 20 

1st Pacific Addivitive Manufacturing Forum 24 

Delivering skilled workers to resources sector 25 

ONE ON ONE 

Mike Lawson – Manufacturing Head, DIISR 26 

AUSTECH PREVIEW 

Austech – stronger than ever 28 

CUTTING TOOLS 

Cutting tales 74 

Avalon Airshow 2011 – huge success for 

Sandvik Coromant 76 

Theory and practice – Walter & West Saxon 

University 77 

Multi-Master – 10 years of service & 

going strong 78 

MOTORS & DRIVES 

Direct drives for cooling tower applications 84 

New Demag rotar motor goes green 86 

High performance drives for port facilities 88 

CNC CONTROLLERS 

New CNC gear & software spur shop-floor 

productivity 92 

Perfectly tailored – Siemens new system 

for compact class 95 

Fanuc – latest generation of CNC controllers 96 

COMPRESSORS 

Two variable outputs doubles benefits 98 

Sullair’s Champion V-Series variable 

speed drives 100 

Cheap choice or costly consequence 103 

AMTIL FORUM 

Finance - Insurance cover - the real cost 104 

OHS – How to find money for OHS 105 

Law – Who owns the mould 106 

Preview 

Lead Story 28 

Austech stronger than ever 

To date, 137 exhibitors from around the country have registered for Austech, to 

be held in Melbourne’s Exhibition Centre on 24-27 May. The event will occupy 

5833m² of floor space. Some, 10,000 + visitors are expected over the four 

days, further demonstrating the renewed confidence in Australian manufacturing. 

Austech and National Manufacturing Week (NMW) will line up alongside the 

Ausplas international plastics industry exhibition, making this a truly special event. 

Some additional initiatives are innovateAustralia, the Manufacturers’ Showcase 

Pavilion, Manufacture Link and the new Additive Manufacturing pavilion. 

Cutting Tools 80 

Improving economics for machining 

cavities in hardened steel 

Stay in control 

Today's 'Open' CNC controllers are more 

than just fast computers; they are the front 

line interface that allows for the generation 

of very complex multi-axis machining 

strategies relatively easily. Further, they 

offer tool-offsets at a push of a button, 

allow servomotors to be tuned on the fly, 

and automatically handle the replacement 

of broken tools. And they provide control 

over processes. 

Want to improve process economics 

for roughing mould cavities in 

hardened stock Take a tip from 

Minco Tool and Mould Inc. As 

a mould manufacturer, Minco 

improved its cavity hogging and 

reduced bottlenecks in a key 

operation on a popular hardened 

stock with a facemill featuring three 

flutes with six-sided inserts. 

CNC Controllers 90 

COVER DETAILS 

Excitement is mounting for the Austech exhibition, to be held in Melbourne’s 

Convention & Exhibition Centre on 24-27 May. 


New Technology: Twisted coolant hole 

Improved Chip evacuation performance 

New Chipbreaker 

Covers a variety of workpiece materials 

MEGACOAT 

New Grade 

PR1230 (Carbon Steel) 

PR1225 (Stainless Steel, Low Carbon Steel) 

PR1210 (Cast Iron) 

Precise Drilling: 

Balanced System 

Better Surface Finishing 

MagicDrill DRX 

Authorised Distributors: 

New South Wales 

Wise Tooling Pty Ltd 

Picnic Point 

Tel: +02 9773 1840 

Email: wisetool@gmail.com 

Victoria 

JPB Cutting Tools Pty Ltd 

Mooroolbark 

Tel: +03 9727 2607 

Email: jpbcutt@ozemail.com.au 

Queensland 

Wallers Precision Tooling 

Towoomba 

Tel: +07 4633 3774 

Email: ayrcross@bigpond.com 

West Australia 

UTG - Australia Pty Ltd 

Dalkeith 

Tel: +412 009 582 

Email: dektooling@ozemail.com.au 

Bromach Pty Ltd 

Sutherland 

Tel: +02 9525 0666 

Email: bromach@bigpond.com 

Precision Tools Service Australia Pty Ltd 

Sunshine 

Tel: +03 9312 5148 

Email: info@ptsaustralia.com.au 

Wallers Precision Tooling 

Mackay 

Tel: +07 4952 3336 

Email: wptmackay@bigpond.com 

Precision Tools Service Australia Pty Ltd 

Kalamunda 

Tel: +0418 948 755 

Email: lenbenjamin@bigpond.com 

D.E.K Tooling Supplies Pty Ltd 

Nerellan 

Tel: +02 4647 2332 

Email: dektooling@ozemail.com.au 

Glory - ETP 

Beresfield 

Tel: +02 4966 5047 

Email: pete@gloryetp.com.au 

D&D Barry Pty Ltd 

Tel: +03 8588 1126 

Email: sales@ddbarry.com.au 

Advanced Tooling Supplies 

Brisbane 

Tel: +07 3881 0008 

Email: advancedts@lizzy.com.au 

South Australia 

Toolprocure Pty Ltd 

Glynde 

Tel: +08 8337 3941 

Email: info@toolprocure.com.au 

For more information: 

Email: ceratip@kyocera.com.sg 

http://www.kyocera.com.sg 


7

EDITOR 

in Chief 

CONTRIBUTING 

EDITORS 

Martin Oakham 

moakham@amtil.com.au 

Ph: +61 3 9800 3666 

Fax: +61 3 9800 3436 

Nina Hendy 

nina@ninasword.com.au 

Ph: +61 3 5333 4939 

ADVERTISING Anne Samuelsson 

SALES 

asamuelsson@amtil.com.au 

MANAGER Ph: +61 3 9800 3666 

Fax: +61 3 9800 3436 

Editorial 

Martin Oakham 

Editor in Chief 

PUBLICATIONS 

co-ordinator 

Gabriele Richter 

grichter@amtil.com.au 

Ph: +61 3 9800 3666 

Fax: +61 3 9800 3436 

PUBLISHER 

DESIGN: 

Shane Infanti 

sinfanti@amtil.com.au 

Ph: +61 3 9800 3666 

Fax: +61 3 9800 3436 

Graphic Heart Pty Ltd 

COVER DESIGN: Typographics 

PRINTER: 

Printgraphics - Australia 

Post all correspondence to: 

Australian Manufacturing Technology 

Suite 1, 673 Boronia Road, 

Wantirna, Victoria 3152, Australia 

Copyright Australian Manufacturing Technology 

(AMT). All rights reserved. Magazine or part 

thereof may not be copied or reproduced without 

written permission by the publisher. Contained 

specifications and claims are those of the 

manufacturer. 

Disclaimer: The opinions expressed by AMT 

contributors or editorial staff are not necessarily 

those of AMTIL. 

AMT is dedicated to Australia’s machining, 

tooling and sheetmetalworking industries and is 

published monthly (10 issues). Subscription to 

AMT (and other benefits) is available through 

AMTIL associate membership at $120pa. 

Suite 1, 673 Boronia Road, 

Wantirna, Victoria 3152. 

Ph: 61 3 9800 3666 

Fax: 61 3 9800 3436 

www.amtil.com.au 


InovatIon Has a new name 

3 Helical cutting edges for 90 degree milling 

Internal coolant supply 

Cutter bodies do not require modification 

for insert mounting with corner radius 

High relief for ramp-down application 

Unique angled screw clamping gives 

increased insert stability 

 

 

 

 

 

TaeguTec Australia Pty Ltd. 

Unit 53/9 Hoyle Avenue Castle Hill NSW 2154, Australia 

Tel: + 61 2 98948077 Fax: + 61 2 98949077 E-m ail: sales@taegutec.com.au http://www.taegutec.com 


9

Innovation – creating and 

unlocking ideas 

From the Minister 

Senator Kim Carr, 

Minister for Innovation, Industry, 

Science and Research 

usinesses are being urged to embrace new ideas and 

research to bolster manufacturing and work towards a 

cleaner, greener and more skillful Australia. 

Innovation Minister Senator Kim Carr stressed the need for 

collaboration as he launched the latest Innovation Showcase 

at the MCG in Melbourne featuring companies exhibiting 

hi-tech products made possible with help from the Australian 

Government. 

Senator Carr praised the stand-out achievements of the 

15 companies featured and said they were terrific examples 

of the Showcase’s theme: powering productivity through 

collaboration. 

“These companies illustrate the fact that partnerships 

between government, researchers and industry are the key 

to turning the best and brightest ideas into reality,” Senator 

Carr said. 

“Our innovators must work hand in hand with our manufacturers 

so that productivity can be the foundation of our 

national economy. 

“We can lead the world in commercialising cleaner, more 

efficient, and globally competitive products and technologies. 

AquaGen Technologies Pty Ltd, for example, has worked out 

how to harness energy from ocean waves. Indice EcoTech has 

produced a device that increases the efficiency of power controls, 

and MicroHeat Technologies’ water heating system will 

help cut water and energy use for business and home-owners. 

“Our manufacturers can make the energy efficient, clean 

and green goods that customers demand. These innovative 

companies are contributing to that ideal of a healthier Australia, 

and making it possible to export our green technology 

globally. 

“Together we will build a richer, fairer and greener Australia.” 

The Gillard Labor Government, through Innovation Australia, 

has a number of innovation assistance measures, including 

the R&D Tax Concession, Commercialisation Australia 

and venture capital programs that allow companies to develop 

and commercialise their inventions to benefit all Australians. 

These programs, together with other support such as that 

provided through Enterprise Connect, Cooperative Research 

Centres and advice from the Industry Innovation Councils 

are all targeted at boosting Australia’s productivity. 

For more information on the range of assistance measures 

available visit www.ausindustry.gov.au and www.innovation. 

gov.au, call 13 28 46 or email hotline@ausindustry.gov.au. 

A new wave of manufacturing 

From the CEO 

Shane Infanti 

CEO AMTIL 

or those who have not become accustomed to the new 

terminology surrounding Direct Digital Manufacturing, 

I suggest you do so. The advancements that have been 

made, and are being made, in this area are quite significant. 

I would be surprised if most manufacturers are not touched 

by components using this process in the near future, even 

traditional manufacturing companies. 

Direct digital manufacturing, sometimes called rapid, 

direct, instant or on-demand manufacturing, is a manufacturing 

process which creates physical parts directly from 

3D CAD files or data using computer controlled additive 

and subtractive fabrication and machining techniques with 

minimal human intervention. 

It is the Additive Manufacturing (AM) component that 

is of real interest. Also called freeform fabrication, rapid 

prototyping, layered manufacturing of 3D printing; this 

technique was originally used to make prototypes of parts 

by physically constructing 3D geometries from material such 

as epoxy resin, ABS and other polymers. 

Nowadays, the speed, reliability and accuracy of the 

equipment used had improved to the extent that production 

applications can be considered as cost effective means to produce 

complex parts. Also, a broad array of materials including 

metals such as titanium and Inconel are being utilised. More 

recent technologies such as selective laser sintering, direct 

metal laser sintering, fused deposition technologies, polyjet 

matrix and inkjet technologies are being improved to the point 

that traditional manufacturing processes for some parts may 

become obsolete in the future. 

If these terms are new to you then take the time to investigate 

the potential applications of direct digital manufacturing 

in your business. Gone are the days when this was just 

for R&D or prototyping. AM is more energy efficient than 

subtractive techniques, there is little or no waste involved in 

the process, speed can be improved in manufacturing parts 

since no tooling is required and more complex components 

can be produced. 

This year at Austech will see the introduction of an Additive 

Manufacturing Showcase. With the support of companies 

such as XYZ Innovation, Camplex, Hi-Tech Metrology, Rapid 

Concepts, 3D Printing Systems, Benson Machines, Rapidpro, 

Formero and RMIT University, AMTIL has put together a 

static display highlighting to visitors the technology behind 

additive manufacturing and the benefits of the process. Austech 

runs from 24-27 May at the Melbourne Exhibition Centre in 

conjunction with Ausplas and National Manufacturing Week. 

To register for the show visit www.austechexpo.com.au 


Time for a new approach to 

workplace training 

From the Industry 

Heather Ridout – 

Chief Executive Australian Industry Group 

t is becoming increasingly clear that Australia’s approach 

to workforce training needs a major overhaul. Layers 

of red tape together with the fragmented nature of the current 

training is obscuring the many positive elements that 

exist and ultimately, is failing to address the intensifying 

skill shortages across the economy. 

To tackle this urgent issue, it is critical that industry 

is given a stronger role in our training system to ensure 

training is focused on the right areas, is well directed and 

consistent with the needs of our economy. The policies, 

initiatives, funding and research activities focused on workforce 

development need to be consolidated in a national 

workforce development strategy. To achieve this, Ai Group 

has proposed the establishment of an Australian Workforce 

Development Agency as a matter of urgency. 

According to Skills Australia, we need an additional 

240,000 skilled workers over the next five years to meet the 

needs of an economy on the brink of unprecedented growth. 

Of particular concern is the inadequacy of our workforce’s 

foundation skills. 

Research shows 46% of Australia’s working age population 

(equating to 7 million adults) has literacy scores 

below the minimum required to function fully in life and 

work. In terms of numeracy it was 53% or 7.9 million 

below the required level. Failure to develop these skills 

will result in decreased productivity and profitability 

across the economy. 

Safety In Action 2011 

The Safety In Action and Melbourne Materials Handling 

trade shows returned last month to the Melbourne Exhibition 

Centre. More than 300 exhibitors across three 

acres offered workplace safety products and services to 

crowds of around 10,000 visitors over the show’s three 

days from 5-7 April. 

Together, the shows are Victoria's largest dedicated 

OHS event and organisers say it owes its popularity to 

the breadth of products and services on show. This year, 

however, a greater emphasis was placed on the advice 

to match with a series of free harmonisation seminars 

open to attendees. 

"The harmonisation of OHS laws has certainly brought 

renewed attention to compliance issues," says organiser, 

Marie Kinsella of Australian Exhibitions & Conferences, 

"but visitors tell us they come with specific OHS challenges 

in mind because they know Safety In Action and 

Melbourne Materials Handling has practically every 

solution on offer under one roof." 

One of the life-saving devices showcased at Safety In 

Action was described as the world's first pocket defibrillator 

by Staying Alive Paramedical Services. The small 

Given the skills gap, it's not surprising the Australian 

skilling system is underfunded – in the vicinity of $660m 

per annum. However, the problem will not be fixed simply 

by increasing funding. Nor will it be fixed just by focusing 

on skills. We need, instead, to move to a workforce 

development model focused on industry need and industry 

engagement, including improved and more effective financial 

engagement from industry. 

The creation of the Workforce Development Agency would 

see the consolidation of programs related to workforce development 

brought into one body thereby sharpening the economic 

focus of the system and strengthening industry's voice. Pivotal 

to its success would be its close working relationship with 

Skills Australia and the industry skills councils to develop 

and implement short and medium term workforce development 

strategies and solutions in partnership with Government. 

This Agency would take a fresh approach to improving 

the quality and relevance of workforce training solutions; 

co-ordinating and integrating enterprise stream funding 

according to workforce development needs; reforming the 

apprenticeship system by removing duplication and administrative 

red tape; focusing strongly on the development of the 

foundation skills of literacy and numeracy, and revitalising 

the development of management skills. 

This new approach to workforce development in Australia 

would be a much needed reform of the system, not another 

re-jigging. This Agency would be critical in the delivery of 

skills in this country and indeed the future of many important 

industries which are currently unable to access the skilled 

labour they desperately need. Industry will be looking for 

urgent Government support of the proposal together with 

a major focus on skills in this month's Federal Budget if 

we are to boost productivity and capability for the future. 

device makes defibrillation a reality for outdoor workers, 

while the larger FRED EasyOnline is monitored over the 

internet for enhanced safety and reliability. 

Night and outdoor workers will also appreciate safety 

vests that can be seen up to 800 metres away at night from 

Baker & Farrow. The vests shine without any other light 

source and are said to offer a 400% increase in visibility 

compared to standard retro-reflective tape. 

www.safetyinaction.net.au 


11

Industry News 

Carbon price talk puts solar on front burner 

Australian clean energy company SilexSolar has ramped 

up production of solar cells and modules by 300% at its 

Sydney Olympic Park plant, driven by household demand. 

Australia’s only manufacturer of solar cells, SilexSolar 

recently introduced a new factory direct online service for 

retailers of PV panels, cutting costs for energy-conscious 

consumers and maintaining a competitive edge against 

imported solar modules. 

SilexSolar General Manager Rod Seares said that the success 

of SilexSolarDirect combined with high profile media 

discussions around the carbon tax were driving awareness 

of the benefits of clean power. 

“People are increasingly conscious that they will need 

to address energy prices literally in their own backyard,” 

Seares said. “We recently installed a new assembly robot and 

one of the largest laminators in the Southern Hemisphere, 

which means we are well equipped to handle this growth 

in throughput -- it is tremendously exciting. 

“As Australia’s only solar cell manufacturer, we are delighted 

both to see demand growing for our solar modules 

and to continue our drive towards lower production costs.” 

SilexSolar employs over 100 people at Olympic Park, 

where production was increased to 24 hours a day, seven days 

a week some months ago in anticipation of rising demand. 

“Expanding employment opportunities at Australia’s only 

solar cell facility is a privilege,” Seares said. “Hundreds of 

jobs were nearly lost when the former owners closed the 

plant in 2008. Not only did we save the facility, we have 

expanded and improved the infrastructure and are working 

on new models with even greater efficiency. We are just 

getting started.” 

Whilst the Australian solar market has seen growth of 

up to 400% in recent years, it remains extremely volatile 

due to its reliance on State and Federal support. 

“Like many other businesses in Australia who are working 

towards a clean energy economy, stability is key.” 

www.silexsolar.com.au 

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13

Industry News 

Walter expands its range of services 

with a Smartphone app 

From accessing important tool data to placing orders online 

in the Walter Toolshop: Walter Tools & More app enables 

users to do both while on the move. Users can, with their 

iPhone, determine cutting parameters for tools for the 

required operation and also place their orders online conveniently. 

This new app developed by Walter is available 

free of charge in 23 languages. 

Calculating cutting data while being away from your 

desktop PC, comparing the cost efficiency of two tool solutions, 

ordering tools and accessing rich online content from 

Walter is made easy. The new smart-phone application Walter 

Tools & More makes all this quick, convenient and possible 

while on the go. Tools & More provides a user-friendly interface 

and a wide range of functions. "With Walter Tools & 

More, customers benefit from our comprehensive machining 

expertise while they are on the move", says Andreas Evertz, 

Chief Executive Officer at Walter AG. "This demonstrates 

our aim to provide our customers, besides excellent products 

our comprehensive service which makes them even more 

efficient in their operations." 

With Tools & More, Walter is the only manufacturer on 

the market with a smartphone application for working out 

detailed cutting data calculations. 

The app can be used to calculate the parameters for: 

• face, shoulder and slot milling processes 

• hole making, including both drilling and boring 

• turning (ISO turning and grooving). 

For these operations, you can calculate the torque, driving 

power and machining volume, main cutting time, cutting 

Gripping technology 

force and also chip thickness. The calculator also takes the 

material group, rake angle, machine efficiency and wear 

factor into consideration. 

The savings calculator provides quick and easy cost 

comparison between two tool solutions. One can compare 

properties like: costs for indexable inserts and bodies, the 

machine setting and the presetting hours, the spare machine 

capacity, as well as the savings per component and 

per batch or year. 

Using Walter Tools & More, users can access online 

resources, a comprehensive package of web-based applications 

and websites. The online resources include, among 

others, the TEC + CCS software from Walter, which assist 

the user with targeted search for the most economical solid 

carbide tool or HSS boring tool, threading tool or milling 

cutter from the competence brands Walter Titex and Walter 

Prototyp. After entering the relevant parameters such 

as application, material, machine and cutting data, TEC + 

CCS determines the best available tool solution – including 

possible alternatives. The result shown comprises not simply 

the cutting data, but also an associated cost calculation. 

Using the app, the user can order the right tools online via 

the Walter Toolshop. This solution provides a time-saving 

ordering process, access to entire range of standard tools, 

up-to-date stock information as well as a clear overview of 

the ordering and billing history. Walter Toolshop is available 

24/7 throughout the year. This solution also prevents 

an order from being entered twice. 

Walter Australia Pty Ltd - 03 8793 1000 

www.walter-tools.com 

During the 41st International Robotics 

Symposium, Heinz-Dieter Schunk, 

CEO of Schunk, received the 

Engelberger Robotics Award. The 

Engelberger Award is considered to 

be the most prestigious award in the 

robotics field. It honours individuals 

that have provided outstanding 

contributions in areas of technology 

development, application, education 

and leadership. 

The award is named after Joseph 

F. Engelberger, the founder of industrial 

robotics and father of the 

modern robotics industry. 

The prize has been awarded by 

the Robotic Industries Association 

Heinz-Dieter Schunk with his award 

agencies make up the 250 members 

of the RIA. 

Schunk is a pioneer in the 

field of gripping technology. He 

recognised early on, that gripping 

would play a leading role 

in automation and robotics. He 

was one of the first engineers to 

develop standardised gripping 

modules. 

Today, Schunk is considered 

to be the worldwide competence 

leader in clamping technology and 

gripping systems with the Schunk 

program having more than 10,000 

standard products. 

As a pioneer in modular robotics, 

(RIA) trade organisation in North America since 1977. 

Leading robot manufacturers, suppliers and system 

integrators, operators, research groups and consulting 

the company offers a vast modular system 

from which various robot structures for industry and 

research can be individually configurated. 


Industry News 

Robotics a manual handling and 

productivity solution 

Robotics may be an ingenious solution for employers 

in the manufacturing sector struggling to drive down 

injuries associated with manual handling. That will 

be the message from robotics consultancy Robotize 

at this year's Melbourne Materials Handling show 

from 5-7 April. 

Robotize director Wade Leslie pointed to statistics 

released in February by Safe Work Australia showing 

manual handling caused 41% of all serious workers' 

compensation claims. Injuries associated with body 

stressing left those injured unable to return to work 

for a median 4.7 weeks. 

"The best solution is to redesign tasks to eliminate 

the possibility of injuries caused by body stressing 

and robotics can provide the ultimate answer," says 

Mr Leslie. 

WorkSafe Victoria's guide Manual Handling in 

the Automotive Industry recommends robotics to 

control several major hazards involving loading/ 

unloading production plant (presses, lathes etc); loading 

and unloading stillages and pallets; and using hand tools. 

Packing and inspecting products, weighing, palletising 

were the areas identified by WorkSafe Victoria in its Guide 

to Manual Handling in the Food Industry where robotics 

could be used to eliminate manual handling hazards. 

As well as the occupational health and safety benefits 

of automating hazardous manual handling tasks, Leslie describes 

the ease and speed with which a robot can perform 

a task like palletizing as "phenomenal". 

"Of course, it is essential to remember that the role of 

workplace safety doesn’t end once a manufacturing task is 

robotically automated," he says. "Operating a secure robotic 

environment involves an entirely new set of protocols; 

otherwise you’re simply replacing the risk of injury from 

manual handling to something entirely more hazardous. 

"Fortunately, there are specialist robotic integrators 

who are experts at providing an array of safety options and 

instructing the manufacturer on which ones are the most 

appropriate for their application." 

To see robots focused on the tasks of picking, packing and 

stacking, visit Robotize at Melbourne Materials Handling 

when it runs concurrently with Safety In Action from 5-7 

April at the Melbourne Exhibition Centre. 

For more information, visit robotize.com.au, www. 

safetyinaction.net.au, email safetyvisitor@aec.net.au or 

phone Australian Exhibitions & Conferences Pty Ltd on 

03 9654 7773. 

Realtek 

metal plastics nano 

2/148 Northern Road, 

West Heidelberg VIC, 

3081 

T> 03 9457 6377 

F> 03 9459 4695 

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15

Industry News 

Dassault Systèmes acquires Intercim 

Dassault Systèmes is now offering the world's first end-to-end 

Product Lifecycle Management (PLM) system following the 

acquisition of process execution software specialist Intercim. 

The $US 36.5m acquisition allows Dassault Systèmes 

to combine its Delmia 3D virtual production software with 

Intercim's software solution for a paperless manufacturing 

execution system (MES) on the shop-floor. 

Dassault Systèmes Australia General Manager Gilles 

Cruanes says the combination of Delmia and Intercim brings 

digital continuity to real-life factory operations. 

"With digital continuity between design and shop floor, 

customers can now fully leverage 3D digital for all functions 

in the production chain - from concept design through to 

product delivery," said Cruanes. 

"This provides the ability to achieve real-time visual 

status and control, and predictable product quality. The 

results for customers are cost savings through better visibility 

of unplanned events, decreased cycle times and better 

material management." 

Cruanes said the combination of virtual production 

and production execution software delivers unprecedented 

advantages for customers in advanced and highly regulated 

industries. 

"Product innovation requires production innovation. 

"Our Delmia virtual production platform has previously 

allowed 3D simulation of manufacturing environments, 

but for the first time we can complete the PLM loop with a 

single, integrated, tool." 

Energy Minister Peter Collier has welcomed the official 

opening of Western Australia’s newest clean energy 

project, the Mt Barker Wind Farm. 

Developed on a private sheep property north of the 

Great Southern town, the site is expected to generate 

about 8400 megawatt hours of electricity each year from 

three 800 kilowatt turbines - enough to power up to 1500 

homes in the Plantagenet Shire. 

“The facility is expected to reduce greenhouse gas 

emissions by more than 8000 tonnes of carbon dioxide 

each year,” Collier said. 

“Power from the wind farm will be purchased under 

a long-term agreement by energy retailer Synergy and 

fed into the South West Interconnected System.” 

The wind farm’s owners, Mt Barker Power Company 

Pty Ltd, engaged SkyFarming of Fremantle to develop 

and build the 73m tall wind generators that support the 

local electricity system. 

The Mt Barker Wind Farm was partly funded with 

$4.2m from the Renewable Remote Power Generation 

Program (RRPGP), an Australian Government-funded 

initiative managed by the Office of Energy in WA. 

A similar capital outlay was provided by major investor 

and project partner Advanced Energy Resources. 

Dassault Systèmes partner Memko, which has been a 

reseller of Intercim software in the Asia Pacific since 2008, 

says Intercim's integration with Delmia presents a great opportunity 

for complex and highly regulated organisations 

to transform operational productivity. 

"In Australia and across multiple industries the overwhelming 

majority of work instructions are still paper-based, 

and most of the market is largely unaware of the benefits 

a paperless solution like Intercim can offer," said Memko 

Director Miro Miletic. 

"This extension of digital PLM from design to process 

execution provides a totally new way of operations, transforming 

organisational efficiency and understanding and 

preventing defects. 

"Users are able to view and interact with the 3D model 

to collect data and identify potential defects, thus improving 

yield while decreasing the cost of rework and scrap. 

"Eliminating paper on the shop floor also consolidates 

various electronic shop-floor information formats into a 

single revision-controlled electronic record that facilitates 

smooth process flow. Ultimately, manufacturing quality 

and through-put is improved." 

"Engineers are empowered within manufacturing operations 

to ensure their designs are compliant, so each 

unit produced is 'built right' the first time and is certified 

to operate," he said. 

"The system also provides a complete 3D-as-built history 

for immediate traceability. 

State Government welcomes WA’s 

newest wind farm 

Mt Barker Wind Farm construction. Photo Peter Auer 

“This development supports initiatives the Liberal- 

National Government has already announced and introduced 

to diversify the State’s energy sector and deliver a 

cleaner energy future for WA,” the Minister said. 

“It also supports the direction of the Strategic Energy 

Initiative: Energy 2031, which will provide a practical plan 

to meet our energy needs for the next 20 years.” 


"The Federal Government's trade policy review announced 

today by the Trade Minister, Dr Craig Emerson, represents 

a sensible stock take of Australia’s global trade agenda and 

provides a renewed focus on the importance of supporting 

trade in the national interest," Australian Industry Group 

Director International Innes Willox said today. 

"Ai Group supports the principles of free trade, including 

the government’s five key policy objectives. Properly 

negotiated liberalised trade outcomes have the potential to 

significantly boost productivity and Australia’s international 

competitiveness. 

"These agreements need to create a truly level playing 

field for Australian industry, especially at a time when it is 

competing in a global market with the Australian dollar at 

post-float highs, patchy conditions across sectors and high 

interest rates in comparison to our major trading partners. 

Agreements do not knock down doors to immediately create 

new export opportunities in new markets, rather, Ai Group 

members find that free trade agreements provide the most 

benefit when Australian companies already have a foothold 

in that market. This is especially so in an international 

economy still recovering from the global financial crisis 

where behind the border trade restrictions in many of our 

key trading markets have clearly increased. 

Industry News 

Trade review provides a renewed focus 

on trade outcomes 

"The government's commitment to focus FTA negotiations 

on markets where Australian industry already has a 

strong trading relationship makes particular sense, especially 

with Japan, South Korea, China and Indonesia - all of which 

are in Australia's top 10 export destinations. However, the 

completion of these agreements need to deliver the most 

comprehensive, reciprocally liberalised outcomes possible. 

The next big test will likely be completion of the Korea 

FTA and the negotiated tariff outcomes on vehicles and 

automotive components. 

"The government's continued support of Doha is 

important. However, we have reached a point where the 

global community needs to bite the bullet and finalise 

the round or walk away, so we can focus on a bilateral 

and regional trade agenda that will specifically benefit 

Australian industry. Talks over the next few months at 

senior officials level will be vital to determining the success 

or failure of Doha. 

"It is crucial that the trade promotion and facilitation 

strategies supporting this Trade Policy Statement, such as 

the Export Market Development Grants Scheme, are fully 

funded in the upcoming Budget so that the programs can 

be reliably effective in supporting the competitiveness of 

Australian exporters of goods and services," Willox said. 

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17

Tech News 

Germany: Lightning-fast materials testing using 

ultrasound 

Ultrasound has been a valuable tool in non-destructive 

materials testing. However, the demands of modern production 

conditions are increasing all the time. Researchers 

at Fraunhofer have now developed a new, more reliable 

process that delivers testing results at a rate that is up to 

a hundredfold higher. By adapting the conventional sonar 

procedure, they have generated 3D images with the aid 

of innovative software and increased the testing rate a 

hundredfold. They no longer use the sonar method that 

emits a sound field in just one particular direction. Instead, 

a probe is used to generate a defocused, non-directional 

wave that penetrates the material. Imperfections are 

easy to identify. The startling thing is that a fissure is 

now visible even if the ultrasound was not specifically 

directed at it. 

Fraunhofer 

Canada: Power tool vibration research 

Workers who employ handheld power tools can be exposed 

to large levels of vibrations in their hands and upper arms. 

Such vibrations are not without consequence. "Prolonged 

exposure to intensive tool vibration can cause hand-arm 

vibration syndrome," says Subhash Rakheja, a professor 

in Concordia University. He has published widely on 

the ills of vibration overexposure and prevention and has 

worked extensively to develop best workplace practices, 

which have led to International Organization for Standardization 

(ISO) for whole body vibration (ISO 5982) and 

for hand-arm vibration (ISO 10068). A world standard for 

anti-vibration gloves is now being investigated. 

Concordia University 

Germany: Extreme testing for rotor blades 

Wind turbines are growing bigger and bigger – the diameter 

of their rotor blades could soon reach 180m. But that 

creates a need for larger test rigs capable of accommodating 

the blades for load testing. One of the largest-ever 

experimental test rigs, for blades measuring up to 90m 

in length, will shortly go into operation. The prototypes 

of new blades have to be tested and certified before they 

can go into production, and that requires equally as large 

testing facilities. Fraunhofer’s IWES Institute will be 

inaugurating a new facility with the capability of testing 

rotor blades up to 90m long. The central feature will be 

a tiltable 1000 metric ton steel and reinforced concrete 

mounting block. Hydraulic cylinders used to tilt the block 

and additional cylinders to load the blade will allow the 

rotor blade to be easily bent. A unique testing setup allows 

for the blade tip of 90m blades to be bent through 

a distance of 25 meters. The hydraulic tiltable mounting 

block allows the setting up of the ideal configuration for 

conducting tests with high precision in a minimum amount 

of time. During the testing, the blade is subjected to the 

same loads that it would normally have to withstand in 

20 years of operation 

Fraunhofer 

Canada : Permanent anti-fog coating 

Researchers at Université Laval have developed the 

first permanent anti-fog coating. which could eliminate 

the fog on eyeglasses, windshields, goggles, camera 

lenses, and on any transparent glass or plastic surface. 

Researchers used polyvinyl alcohol, a hydrophilic 

compound that allows water to spread uniformly. The 

challenge was to firmly attach the compound to the 

glass or plastic surface. To accomplish this, researchers 

applied four successive layers of molecules, which 

formed strong bonds with their adjoining layers, prior 

to adding the anti-fog compound over this base. The 

result was a thin, transparent, multilayered coating 

that does not alter the optical properties of the surface 

In addition, the chemical bonds that join the different 

layers ensure the hardness and durability of the entire 

coating. Existing anti-fog treatments don’t have these 

properties and won’t withstand washing, whereas this 

coating is permanent. 

Université Laval 

Poland: Innovative new laser 

The Institute of Physical Chemistry of the Polish Academy 

of Sciences and the Warsaw University work have 

started construction of an innovative laser. The compact 

device will make use of a unique light amplification 

technology to allow single laser pulses to reach the 

power of tens of terawatts with world record-breaking 

amplification parameters. 

Polish Academy of Sciences 

USA: Progressing towards hydrogen vehicles 

Researchers have revealed a new single-stage method 

for recharging the hydrogen storage compound ammonia 

borane. The breakthrough makes hydrogen a 

more attractive fuel for vehicles. Hydrogen is in many 

ways an ideal fuel. It possesses a high energy content 

per unit mass, and it can be used to run a fuel cell, 

which in turn can be used to power a very clean engine. 

On the down side, H2 has a low energy content per 

unit volume. The crux of the hydrogen issue has been 

how to get enough of the element on board a vehicle 

to power it a reasonable distance. Work has focused 

on chemical hydrides for storing hydrogen, with one 

material in particular, ammonia borane. Ammonia 

borane is attractive because its hydrogen storage capacity 

approaches 20% by weight - enough that it should, 

with appropriate engineering, permit hydrogen-fueled 

vehicles to go farther than 480km on a single "tank," a 

benchmark set by the U.S. Dept of Energy. This simple 

scheme regenerates ammonia borane from a hydrogen 

depleted "spent fuel" form (called polyborazylene) back 

into usable fuel via reactions taking place in a single 

container. This "one pot" method represents a significant 

step toward the practical use of hydrogen in vehicles 

by potentially reducing the expense and complexity of 

the recycle stage. 

Los Alamos National University 


Industry News 

Expansion plans spur new appointments 

Australian speciality steel business, Interlloy has launched a 

five year vision for growth with the creation of a number of 

new roles including a CEO to drive the business and a Non- 

Executive Chairman to further bolster the Board capability 

and guide expansion plans. 

Robert Barnes, appointed to the role of CEO in February, 

brings to Interlloy many years of senior management experience 

from a diverse range of industries including pharmaceutical 

and consumer goods in domestic and international markets. 

Barnes’ track record brings strong organic growth outcomes 

over many years combined with significant merger, 

acquisition and integration experience, all of which will be 

important to Interlloy’s future growth plans. 

According to Barnes his appointment marks a major transition 

in the development of this 24 year old business with a 

strong history of success. 

“The growth possibility that Interlloy offers is a great 

challenge; to recreate a business building on the success of the 

past with the opportunity of the future,” he said when asked 

what motivated him to join the steels industry. 

That growth intent is further enhanced with the recent sale 

and leaseback of the Interlloy distribution facilities Australia 

wide to ensure appropriate funding for the investments ahead. 

The newly created role of Non-Executive Chairman has 

been filled by John Downes. Downes, Strategy Director at 

the Business Development Company, has been working with 

Interlloy on developing and implementing their business 

growth strategies for the past 12 months. 

“The appointment of Rob as CEO was seen as a critical 

element of the growth plan; bolting a $500m capable CEO onto 

this fast growing business is a master stroke” he said, when 

reflecting on key milestones in the strategy implementation. 

“It’s all about having the right people in place, being accountable 

for doing the right things right, and focused on the right 

outcomes. It sounds simple, but it continues to be the biggest 

single issue facing CEOs and the performance of their businesses 

today That’s why we have put in place a number of strategies to 

focus the business on the few key high impact activities, and it 

is paying off. Revenue and performance are up in the industry 

where there is a struggle for growth and profitability.” 

Downes is one of Australia’s leading business growth 

experts with over 25 years Australian and international experience 

providing strategy and operational advice. Downes 

merged his successful strategy and operations services business 

into the Business Development Company. 

Prior to commencing his own business, Downes was a lead 

consulting partner at Deloitte Private where he advised middle 

market and multinational organisations on their strategy, 

operations, and the technology to support their growth. He 

has worked in Melbourne, Canberra, London and Chicago. 

“I am really excited about helping Interlloy become the 

dominant special steels provider in Australia.” 

CO-LOCATED WITH 

21-23 JUNE 2011 

BRISBANE CONVENTION & EXHIBITION CENTRE 

REGISTER TO VISIT qldSafETyShOw.cOm.au 


19

Government News 

Green manufacturing takes aim at global 

billion dollar market 

A new manufacturing process using organic fibres to make 

planks for shipping pallets has been supported by the Federal 

Government. 

Developed by Biofiba Limited, based at Gosford, NSW, 

and now with funding from the CSIRO’s Australian Growth 

Partnership (AGP), the process will help the company win a 

share of the global pallet market worth billions of dollars a year. 

Wooden pallets take up a large slice of the world’s timber 

consumption. While there are several environmentally 

sustainable processes being developed, most export pallets 

are used once and then consigned to landfill where they 

slowly decompose. 

The AGP program – funded through the Federal Government’s 

extension to the CSIRO’s Flagship initiatives – was 

created to offer funding to small and medium-sized enterprises 

(SMEs) in an area of national priority. The program offers 

between $500,000 and $2m per SME and allows businesses 

to purchase CSIRO research and development capability. 

Announcing the funding, Innovation Minister Senator 

Kim Carr said Biofiba’s technology would allow production 

of timber substitutes from organic fibres and natural starches. 

GM Holden result vindicates new car plan 

“The raw materials come from renewable sustainable 

resources and pallets made from Biofiba composites will 

break down into Earth-friendly, natural matter – delivering 

significant environmental advantages over traditional 

wooden pallets,” Carr said. 

“The Gillard Labor Government is pleased to support 

programs like AGP because they provide a focused and 

customised way to overcome technology challenges. 

“To be able to use the resources of the CSIRO to deliver 

this type of solution that has the capacity to improve Australia’s 

triple bottom line, is an exciting prospect.” 

The CSIRO will invest up to $1.97m to fund a collaboration 

through its Future Manufacturing Flagship to tailor the 

material formulation and high speed production. 

Biofiba’s Managing Director, Laurence Dummett, said 

the company was attracted to the AGP program because it 

could deliver a combination of benefits. 

“The CSIRO’s Future Manufacturing Flagship has the 

facilities to develop the commercial process and to validate 

the products’ biodegradability. AGP offered us access to 

this and funding as well,” Dummett said. 

GM Holden’s $112m after tax profit in 2010 is a resounding 

vindication of the Australian Government’s $5.4bn A New 

Car Plan for a Greener Future and its transformation of the 

Australian automotive industry. 

Congratulating GM Holden, Innovation Minister Senator 

Kim Carr said the result was made possible by hard work under 

a partnership with Holden, the Federal and State Governments, 

unions and workers and was testament to the resilience and 

creativity of the Australian automotive industry. 

“This return to profitability is a $320m turnaround that 

shows that the New Car Plan is working,” Carr said. 

“Not only are domestic vehicle sales for Holden up by 

11% for 2010 compared with 2009, but vehicle exports, to 

Brazil, the Middle East, New Zealand, South Africa and 

North America also underwent a 13% boost. 

“Australian engine exports also rose by 25% and, coupled 

with greater demand for engine products, this led to a second 

production shift at Port Melbourne. The reinstatement of a 

second shift at Elizabeth was also a fantastic result for the 

company and its loyal workers. 

“The fact that there are excellent prospects for further 

export growth at a time of a strong Australian dollar further 

underscores our faith in the company and the industry.” 

Carr said the introduction of the locally produced Holden 

Cruze and the potential for a police variant of the Caprice 

for the North American market would add further strength. 

“This is a company that has also made an exemplary 

commitment to local design and engineering, supported 

by the Australian and State Governments. For example, it 

spent $179m on research and development in 2010, compared 

with $146m in 2009,” Carr said. 

The success of the Australian-designed Camaro in the 

United States is evidence of the expertise of the local operation, 

which is GM’s global centre for large rear wheel 

drive architecture. 

“This result is in no small way due to the efforts of 

GM Holden Chairman and Managing Director Mike 

Devereux, and his staff and workers. I want to particularly 

acknowledge the sacrifices that have been made 

by Holden workers during the hard times of the global 

downturn,” Carr said. 

Bosch restructure 

The Australian Government is disappointed to learn 

that Robert Bosch Australia Pty Ltd will be relocating 

some of its manufacturing operations overseas. Bosch’s 

decision reflects the company’s international commercial 

priorities. Bosch did not speak to the Australian 

Government before making its announcement. 

The Government regrets the decision and will stand 

with workers and the company to minimise the social 

and economic disruption to families. The decision will 

affect some 380 jobs at the Clayton site in Victoria over 

the next two-and-a-half years. Bosch currently employs 

1100 people at Clayton out of a total of over 1800 across 

Australia. The company will honour all employee entitlements 

and offer extensive outplacement and general 

counselling services to those affected. 

Bosch has a strong and on-going commitment to the 

Australian market and community. And, importantly, 

its design and engineering capability will remain in 

Australia — Bosch will continue to manufacture components 

for local markets. 


Take in Alfex fold ad 


21

22 May 2011 Australian Manufacturing Technology 

Take in Alfex fold ad

Industry News 

Safety In Action visitors pack first 

morning seminars 

Safety in Action headline speaker Barry Sherrif 

‘Safety In Action’ visitors recently filled 450 seats to capacity 

and then lined the walls of a Melbourne Exhibition 

Centre hall to hear Barry Sherriff, partner of Norton Rose 

law firm, explain the implications of the new model Work 

Health and Safety Act. The hall was filled once again to 

hear from Safe Work Australia’s Julia Collins. 

The address was the first of three Sherriff, regarded as 

one of the architects of the model laws, presented at the 

Safety In Action and Melbourne Materials Handling trade 

shows last month. The lawyer heads a line-up of experts 

hosting seminars at Safety In Action that includes Julia 

Collins of Safe Work Australia and Carol Bullivant of the 

Australian Industry Group. 

Sherriff told the audience it was “troubling there’s misinformation 

out there being peddled by people.” 

In particular, Sherriff said, middle managers could 

be assured they were not regarded as “officers” under the 

model Act, which is due for adoption around Australia from 

1 January next year. 

“Officers are those who participate in making decisions 

affecting the whole, or a substantial part of, the organisation. 

Contrary to some of the alarming statements being made, 

these are not decisions at the micro level. 

On the other hand, Sherriff said middle managers had 

not escaped responsibility. 

“A word of caution: managers are workers too and have 

a duty of reasonable care to others.” 

Although the consistency brought by the new model Act 

has been applauded by businesses operating in multiple 

jurisdictions, Sherriff said this was not the most important 

outcome of the harmonisation process. 

“The model Work Health and Safety Act delivers much 

more than achieving homogeneity,” he said. “That will not 

be the biggest change across the country. Instead, it is about 

moving safety forwards.” 

It was time to update existing legislation based on the 

40-year-old Robens report, he said. Work was no longer 

undertaken purely by employees but now involved a more 

complex set of relationships that included contractors, subcontractors, 

labour-hire companies and even volunteers. 

“If you look in the model Act for the duties of an employer, 

it will be a fruitless task,” he said. “If you look in 

the model Act for the duties of an employee, it will be a 

fruitless task. Each of these will still have duties, but as part 

of broader classes of ‘business’ and ‘worker’. Workers are 

those who work in any capacity and who are influenced by 

the holder of the primary duty of care. We have not made 

fundamental changes to the legislative model but are bringing 

it up to date. We have made it clearer who owes a duty. 

No longer are your obligations determined by who you are 

but by what you do.” 

Sherriff did not accept suggestions from a Safety In Action 

audience member that the model Work Health Safety 

Act would necessarily impose greater costs on employers. 

“A lot of what we’ve done is to simplify and clarify 

things, to make the law better and remove the legal gobbledygook. 

People in the office, factory, the warehouse, or 

the road who need to understand the safety laws. It requires 

what you should now be doing anyway.” 

Are pre-apprenticeships 

the answer 

Giving would-be apprentices a taste of what to expect 

through pre-apprenticeship training does not necessarily 

lead to increased completion rates or course satisfaction. 

Released by the National Centre for Vocational Education 

Research (NCVER), ‘Preapprenticeships and their 

impact on apprenticeship completion and satisfaction’ 

finds that these courses see only a modest increase in 

satisfaction with job related aspects of apprenticeships 

– nothing that suggests that pre-apprenticeships solve 

many of the issues relating to poor completion rates. 

Dr Tom Karmel, Managing Director, NCVER said 

that no doubt some find a pre-apprenticeship valuable 

for their apprenticeship, but the study provides little 

evidence of much of an effect on overall completion rates. 

“We found that pre-apprenticeships helped a bit in 

construction, food and electro-technology, but appear to 

lower completion rates in hairdressing and automotive 

and engineering. This suggests that getting the design 

of these programs right is a challenge!” 

Copies of ‘Pre-apprenticeships and their impact on apprenticeship 

completion and satisfaction’ are available 

on www.ncver.edu.au/publications/2353.html 


23

Industry News 

1st Pacific Additive Manufacturing Forum 

Additive Manufacturing (AM), also referred to as 3D 

printing, is now playing a major role in a range of key industries 

such as aerospace, automotive and medical where 

it enhances the ability to fabricate complex, functional 

components. AM utilises both metal and polymer-based 

materials to mass manufacture components directly from 

CAD data. 

The products are grown/printed layer by layer without 

the need for time-consuming subtractive manufacturing 

processes such as line set up and machining. As such, 

fully functional components or products can be produced, 

on an ‘as needed’ basis, in groups nested with other components 

or as single items. This dramatically reduces 

the cost of production and the time needed to bring new 

products to market. 

Milan Brandt, Professor of Advanced Manufacturing at 

RMIT and organiser of Pacific Additive Manufacturing 

Forum (PAMF) said that PAMF is the first in a series of 

annual conferences focussing on the application of additive 

technologies in Australia and the Pacific region. PAMF 

aims to bring together industry, 

researchers, and equipment 

suppliers to discuss the latest 

developments and progress in 

AM technology from international 

and local industry practitioners, 

the aim being to share 

knowledge, experiences and 

visions for this technology. 

The one-day Forum in Melbourne 

on 7 June will serve 

as the opening for a series of 

half-day technical presentations 

held in Adelaide, Sydney and 

Brisbane from 8 to 15 June. 

These are organised in partnership 

with the Defence Materials 

Technology Centre and will 

be targeting SMEs currently 

working in the Defence sector, 

wishing to improve their productivity, efficiency and 

competitiveness when sourcing defence contracts. 

“The Forum and technical presentations are an opportunity 

for Australian companies to understand the prospects, challenges 

and opportunities in applying AM technology”, says 

Brandt. “Attendees will learn when it makes good business 

sense to consider AM for part production. They will also be 

introduced to the growing number of opportunities available 

for custom and short-run production, replacement part 

manufacturing, or manufacturing aids, such as jigs, fixtures 

and assembly guides.” 

PAMF builds on the very successful ‘Factory of the Future’ 

series of events organised and supported in 2010 by Formero 

Pty Ltd. Terry Wohlers, an internationally renowned industry 

consultant, speaker and author, will be the keynote speaker 

at the Forum and will also head the series of presentations in 

other capital cities around the world. Wohlers led the ‘Factory 

of the Future’ seminars in 2010, where he was joined by 

speakers from Germany, Korea, 

USA and South Africa. 

The Melbourne event will 

conclude with the opening of 

the RMIT multi-million dollar 

Advanced Manufacturing 

Precinct (AMP). The AMP will 

house the latest in state-of-theart 

AM technology and is aimed 

at creating new opportunities in 

design, innovation and product 

development/manufacture for 

Australian companies in general. 

The AMP will focus on 

advanced product design, materials 

and processes, and aim 

to generate new commercially 

significant intellectual property. 

Brandt said “the additive 

manufacturing path, which was started some 15 years 

ago by a few pioneers, is now a growing technological 

freeway encouraging everyone to get on board, through 

PAMF, for a glimpse of the future.” 

This year at Austech will see the introduction of an 

Additive Manufacturing Showcase. With the support 

of companies such as XYZ Innovation, Camplex, 

3D Printing Systems Hi-Tech Metrology, Rapid 

Concepts, Benson Machines, Rapidpro, Formero 

and RMIT University, AMTIL has put together a 

static display highlighting to visitors the technology 

behind AM and the benefits of the process. Austech 

runs from 24-27 May at the Melbourne Exhibition 

Centre in conjunction with Ausplas and National 

Manufacturing Week. To register for the show visit 

www.austechexpo.com.au 


Delivering skilled workers to the 

resources sector 

An 18 month apprenticeship training program for around 

1000 workers and $200m to fund targeted training projects 

for a range of skills in critical demand are among a range 

of initiatives to address skills shortages in Australia’s resources 

sector. 

Releasing the Government’s response to the National 

Resources Sector Employment Taskforce report, Minister 

for Skills and Jobs, Senator Chris Evans said funding is being 

targeted at practical, industry-based solutions designed 

to deliver skilled workers. 

According to Senator Evans “Under the adult apprenticeship 

project, experienced workers will have their existing 

skills recognised and be given the opportunity to complete 

Iscar appoints new 

Business Development 

Manager 

Iscar is proud to announce the appointment of David 

James as their new Business Development Manager for 

Australia. James has over 25 years experience in the 

cutting tool industry, including several years working 

for Iscar South Africa. 

James’ other achievements include the establishment 

of one of the first Australian tool management facilities 

at a major automotive manufacturer, and heading the 

Australian subsidiary of a multi-national German tooling 

company. 

James will be on duty on every day of the Austech 

2011 exhibition at the Iscar stand. 

AMT_May_Final.pdf 2 11/04/2011 3:00:53 PM 

Industry News 

the competencies required to get a full trade qualification 

in just 18 months. 

“Existing resource sector employees and workers from 

across Australia will be recruited and on and off-the-job 

training provided so companies will benefit immediately 

from a boost to their workforces. 

“Workers with real skills will be able to gain trade 

qualifications in up to 18 months and secure highly paid 

jobs in the sector. 

“The innovation follows the Government’s commitment 

to simplify and reform the Australian Apprenticeship system 

to ensure it is better targeted to meet the critical skills needs 

of the Australian economy.” 

C 

M 

Y 

CM 

Swarf Compactor 

Air Filtering 

See These 

Products on 

Stand 765 

at Austech 

MY 

CY 

Robot & Automation Tooling 

Work Holding Equipment 

CMY 

K 

Coolant & Oil Cleaning 

www.accmfg.com.au 

info@accmfg.com.au | 03 9546 3733 


25

Q A 

OneonOne 

Mike Lawson is the government’s eagle 

eye over the country’s manufacturing 

sector, with a strong understanding of 

the complexities of the Industry. The 

Head of the Manufacturing Division of 

the Department of Innovation, Industry, 

Science and Research, Lawson speaks to 

Nina Hendy. 

AMT: Tell me a bit about yourself, including your professional 

background and how you came to be in your current role. 

ML: 

I was recently appointed as the head of the Manufacturing 

Division of the Commonwealth Department of Innovation, 

Science and Research. I have had a number of roles in 

the Department and its predecessors since 1989, when I 

joined the then Bureau of Industry Economics. Some of 

the many issues I’ve worked on during my time with the 

Department include business finance and taxation, structural 

adjustment assistance for the automotive and textile, 

clothing and footwear industries and linking companies to 

global supply chains, especially for defence projects. 

I have enjoyed working with a range of manufacturing 

industries and have learned a lot from company owners 

and managers about the real issues facing manufacturing 

companies. Some of your readers will know me from our 

work together on the Joint Strike Fighter project. I was 

an economic adviser to Senator John Button in the early 

1990s. I worked in the International Energy Agency, based 

in Paris, from 1994 to 1997. I have a Masters degree in 

economics from the Australian National University. 

AMT: What are some of the most important projects you’re 

working on right now and when will they come to fruition 

ML: Part of the policy advising job of the Manufacturing 

Division is ensuring that the Government understands the 

issues facing the manufacturing industry when decisions 

are made. I hope I do a good job translating between manufacturing 

business people around Australia and policy 

people in Canberra, because sometimes they don’t speak 

the same language. 

The Government recently announced that it intends 

to introduce a carbon price from July 2012 to move the 

Australian economy to an economic growth trajectory 

that is less carbon intensive. Clearly there are both challenges 

and opportunities for the manufacturing sector in 

adjusting to this challenge. One major issue is manufacturers 

have to compete with producers in other countries 

who may not face the same carbon constraint. The opportunities 

arise from the new products and processes that 

will be required, what some people call ‘green growth’. 

The Government is currently looking at the implementation 

of that policy and complementary measures to assist 

the change, so we are involved in that. I have also been 

involved in the Government’s efforts, though Supplier 

Advocates, to improve the success of Australian companies, 

especially small and medium enterprises, in the government 

procurement market. We have seen some benefits 

here, but a change in culture does not occur overnight. 

AMT: Which sectors of the country’s manufacturing industry 

have the most potential for growth over the next one to 

two years, and what is driving that growth 

ML: Although I was trained in the economic way of thinking, 

which focuses on sectors, I don’t really believe that is the 

best way of thinking about growth potential. I think it is 

about companies rather than sectors. It is people, leadership 

and innovation that drive growth and that happens 

with real people and real companies, not theoretical sectors. 

Industry sector growth is just the summation of company 

growth outcomes. I know great companies in sectors 

that are declining and I know companies that are not doing 

so well in growing sectors. Of course a rising tide tends to 

float all the boats, but not if they have anchored themselves 

to a rock. If they have not invested in innovation, be 

that in products, processes, or new business models, then 

sooner or later their competitive edge will dissipate. 

AMT: What are the most relevant aspects of the government’s 10 

year innovation strategy, Powering Ideas, to the country’s 

manufacturing sector 

ML: The Powering Ideas innovation strategy is a 10 year strategy 

to make Australia more productive and more competitive. 

My personal view is that the services provided 

by Enterprise Connect to manufacturing companies in 

the $2m to $100m turnover range have been especially 


OneonOne 

important. I say that because many company CEOs have 

told me that it has been a great experience for them. 

Enterprise Connect provides a free business review from 

a well-credentialed and experienced business adviser and 

then provides financial assistance for implementing the 

findings of the review. 

The loneliness of the manufacturing CEO, too often working 

in the company rather than on the company, is something 

Enterprise Connect can help with. It is not big bucks 

or a silver bullet, but it does help companies think through 

and implement a business strategy for a long term profitable 

future. 

The change of the R&D Tax Concession to a more generous 

tax credit arrangement will, if it is passed by the 

Parliament, increase the financial support rate for manufacturing 

companies doing eligible R&D, especially for 

small and medium enterprises. 

AMT: What do you predict will be the growth sectors within the 

Australian manufacturing sector in five years’ time 

ML: I am afraid I am too sensitive to the gibe that ‘economic 

forecasting was invented to make astrology look respectable’ 

to pretend that today’s predictions will not change 

as new information comes to light and unexpected events 

occur. 

The big picture is that supply chains are consolidating and 

globalising, and Australian manufacturing companies will 

need to be part of that. What were 52 aerospace companies 

in the USA in 1980 are now five. In the resources sector 

we saw the amalgamation of BHP and Billiton and their 

subsequent takeover of Western Mining Corporation. 

The names of the pharmaceutical companies are getting 

longer and longer as they amalgamate. The story can be 

told for many other sectors. Those global companies are 

consolidating and globalising their supply chains. With 

the re-entry of China and India into the world economy, 

Australian producers are facing new competitors, with 

lower cost structures and increasing quality. The ICT revolution’s 

impact on logistics is accentuating the exposure of 

companies to international competition. Companies that 

have a compelling value proposition for their customers, 

which create value with engineering and design and ‘own’ 

their intellectual property will prosper, but those that rely 

on cost competitiveness in a build-to-print market are facing 

huge challenges. 

Competitive companies linked to the booming resources 

sector have prospered. However, even there we face difficulties. 

For example, the move from stick-build construction 

techniques to pre-assembled modules has massively 

increased the exposure of metal fabrication to international 

trade competition. Some are doing it tough despite 

the boom in their traditional customer market. 

AMT: The Government’s Manufacturing Division worked to improve 

the competitive position of the manufacturing sector 

in 2010. What actual quantifiable difference did it make to 

the sector 

ML: We don’t have a profit and loss balance sheet to tell us 

how we did so that is not an easy question to answer in 

clear, quantitative terms. We do have a budget, but the 

revenue side is rather thin! 

We have a range of measures of the activities we perform 

and the outcomes we are trying to achieve and we report 

on those in various documents like the Department’s annual 

report but they are impossible to objectively summarise. 

The Government has a range of programs extending 

from large expenditure programs such as the Automotive 

Transformation Scheme to modest programs such as 

Commonwealth support for the Industry Capability 

Network. Each program has its own measure that relates 

to what it is intended to achieve, such as the amount of 

investment or numbers of internationally contestable 

business opportunities won by Australian companies. 

Manufacturing is buffeted by so many factors and the outcomes 

are really the result of the hard work of the people 

in the sector, supported by various Government programs. 

AMT: What are the biggest challenges facing the manufacturing 

sector right now and is there anything that the Federal 

Government is working on to improve the situation 

ML: Huge structural change is being driven by the re-entry of 

China and India into the world economy. The resulting resources 

boom has put upward pressure on the exchange 

rate, and China’s export prices are reducing prices of many 

manufactured goods. The Government’s macro-economic 

policies are intended to facilitate adjustment and moderate 

the impact. While we had a remarkable escape from 

the impact of the Global Financial Crisis, this is a longer 

term structural issue. 

The Government’s response to this is to assist companies 

to meet the new competitive challenge by innovation. 

I talked about the innovation programs earlier. The 

Government has also significantly increased expenditure 

on programs to assist the skilling of the Australian labour 

force. The future for Australian manufacturing is not low 

skilled competition with China. The highly innovative, 

highly skilled and successful medium-sized manufacturers 

in Germany that pay high wages, cope with a high exchange 

rate and export great products to the world should 

be our model. 

AMT: What have manufacturers got to look forward to in terms 

of government policy that will help the sector thrive 

ML: Around 3000 manufacturing companies have so far benefitted 

from the Enterprise Connect business review. That 

leaves many more that could make the call to their local 

Enterprise Connect office to see what they have to offer. I 

should also say that Enterprise Connect is a work in 

progress and they are introducing new offerings. The 

Supply Chain Improvement Program has been developed 

to assist companies to develop a culture of continuous improvement 

and to do that within a context of supply chain 

relationships. It has been modified from a successful industry-led 

program that was developed in the United 

Kingdom in the defence and aerospace sector. Enterprise 

Connect is also developing a practical management development 

program for small and medium manufacturing 

companies. Programs like these are designed to help manufacturing 

companies help themselves. 


27

Preview 

Austech – stronger than ever 

Austech 2011, which will be held from 24 - 27 May 2011 at the Melbourne Exhibition Centre, is already 

conjuring up incredible enthusiasm, with the vast percentage of exhibitors being really excited about their 

stands and what they will have on display. As such, AMTIL’s premier event is once again being seen as a ‘must 

attend’ event by the manufacturing fraternity here in Australia. Exhibition organiser, Kim Warren, tells me 

prospective visitors are already talking about turning up with their cheque book open, reinvigorated by the 

upturn in the Australia economy and very keen to invest in tomorrow’s technology. To date, 137 exhibitors 

from around the country have registered, occupying 5833m² of floor space. Some, 10,000 + visitors are 

expected over the four days, further demonstrating the renewed confidence in Australian manufacturing. 

B y M a r t i n O a k h a m 

ith a focus being on new developments in machine tools, manufacturing 

systems, automation, fabrication, precision tools, automation, 

measurement, additive manufacturing and prototyping, there 

will be something for everybody. Further, the manufacturing software 

providers will demonstrate the latest in CAD/CAM, FEA, production 

control, verification, part nesting, all ensuring increased process control 

from art to part. Still further, Austech and National Manufacturing 

Week (NMW) will line up alongside the triennial Ausplas international 

plastics industry exhibition, making this a truly special event. Moreover, 

with its new online presence (www.austechexpo.com.au) Austech now 

provides exhibitors and visitors with an online forum tailored to their 

needs, including easy online registration and stand booking information, 

a list of exhibitors, as well as the latest related news and floor 

plans. 

“Austech ensures that local manufacturers have the opportunity 

to gain comprehensive exposure to the latest technologies that will 

enhance their efficiencies,” says AMTIL’s CEO Shane Infanti. “A drive 

toward improved efficiencies within each company can have effects 

right across the supply chain, thereby increasing the national industry’s 

capability.” 

The presentation of innovative products, solutions and services 

from exhibitors will be supported by a number of initiatives. These 

include innovateAustralia, the Manufacturers’ Showcase Pavilion, 

Manufacture Link and the new Additive Manufacturing pavilion. There 

are also a number of initiatives within NMW, these include: Automation 

& Robotics, Materials Handling, Welding Technology and Information 

Technology Zones. 

innovateAustralia 

The 370m² innovateAustralia showcase differs from previous years, 

in that the main aim is to connect visitors with industry, in line with 

our mantra to ‘connect inform and grow’. “Rather than the usual pure 

technology dissemination, associated with past innovate showcases, 

there will be a positive focus on what the technology offers in terms of 

opportunities and where they lie.” Says Greg Chalker, Project Manager, 

AMTIL. “Visitors will also get to see some of the products that typify the 

opportunities that exist within each sector and discuss what it takes to 

be successful in that space.” 

The initiative has received funding support through AusIndustry’s Industry 

Cooperative Innovation Program (ICIP) Via AMTIL’s Lynx project, 

of which innovateAustralia is a major activity. 

AMTIL’s project team has always taken the view that if it can promote 

the adoption of leading manufacturing technologies, educate companies 

in advanced management methodologies and process techniques, 

then expose them to opportunities, it will place them on a steady foundation 

for competitive growth. “Innovation in manufacturing is key to 

global competitiveness and sustained economic growth, says Infanti. 

“innovateAustralia comes at the right time for manufacturers and users 

to get out and take a good look at the next generation of manufacturing 


methods that can help to apply ‘innovation’ to their business. In addition, 

it highlights business opportunities and the capabilities needed to be involved 

in certain industry sectors.” 

“Manufacturers tell us that one of their largest challenges is staying 

ahead of the innovation curve,” adds NMW Exhibition Director Paul Baker, 

Reed Exhibitions, an innovateAustralia partner company. “In response, 

innovateAustralia has been developed as a tool to help manufacturers get 

hands-on with opportunities that could become the mainstream industries 

in the future.” 

The showcase will highlight vital future growth sectors including aerospace, 

defence, renewable technologies, automotive transport and medical, 

and provide leading companies in these sectors with a platform to 

discuss supply barriers and opportunities with Australian precision engineers 

and advanced manufacturers. As such, the featured ‘Victorian 

Government Opportunity Café’ area will include a timetable for visitors to 

sit down and listen to industry leaders discuss relevant supply chain and 

major project topics in a relaxed informal café setting. “The Café is a place 

for manufacturing visitors to discuss business opportunities, connect 

with innovateAustralia industry leaders and become aware of technologies, 

methodologies and techniques to assist them to improve and grow,” 

explains Chalker. The conversations will be transmitted to speakers over 

the innovateAustralia stand for visitors to overhear. “Visitors will be able 

to listen to open discussions between industry leaders about opportunities 

and topics, informing them of the potential opportunities within the 

sectors, and hopefully seeding growth” adds Projects Coordinator, David 

Creighton. “We have been fortunate enough to attract real industry leaders 

that can provide hard facts about supply chain issues and opportunities” 

Discussions will take place with the Minister for Small Business, Nick 

Sherry, the Defence Global Supply Chain and automotive envoy, Mr John 

Conomos, sitting down, over a coffee. Discussions will also involve representatives 

from: Thales Australia, The Victorian Government, Deloitte, 

ICN, Enterprise Connect, GippsAero, HydroGen, Invetech, the Industry 

Capability Network (ICN), the Defence Material Organisation (DMO) and 

as mentioned previously, the Federation of Automotive products manufacturers 

(FAPM). 

Discussion topics will include innovative ways to access major project 

opportunities, initiatives that facilitate export market development and 

encourage manufacturers to focus on the specific advantages of international 

business, including access to economies of scale and niche growth 

markets. For example, Australian auto component makers from Victoria 

are currently looking to tap opportunities in the Indian market by supplying 

to vehicle manufacturers, which are facing a demand supply gap. The 

Australian industry body Federation of Automotive Products Manufacturers 

(FAPM), which will be represented at the Café, have signed a memorandum 

of understanding with Automotive Component Manufacturers 

Association of India (ACMA). 

Manufacturers’ Showcase pavilion 

The Manufacturers’ showcase pavilion will highlight the capabilities of 

Australia’s precision engineering and advanced manufacturing industry. 

It provides Australian component manufacturers, precision engineering 

firms, toolmakers, advanced manufacturers and general engineering 

companies the opportunity to exhibit their capabilities. “The importance 

of our manufacturers having the opportunity to promote the capabilities 

and capacity they have to offer is critical in view of international competition,” 

explains Infanti. “The Manufacturers’ Showcase provides the perfect 

forum for these companies to put themselves in front of Austech 

visitors, many of whom outsource and contract out their work.” 

“Past exhibitors have indicated that they generated great leads 

over the four days,” adds Austech organiser and AMTIL Event Manager 

Kim Warren. Many of these were from overseas and interstate, 

whom exhibitors would not have otherwise encountered.” 

The Manufacturers’ Showcase initiative is proudly supported by 

ManufactureLink (www.manufacturelink.com.au), Australia’s largest 

industrial manufacturing network. ManufactureLink will exhibit the 

capabilities of its network of more than 400 advanced manufacturers 

in the centre of the Showcase Pavilion. Managing Director George 

Pofandt will be on hand to assist Austech attendees to locate the 

manufacturing capability they need and provide advice on how best to 

manufacture their products. 

Additive/Digital Manufacturing Showcase 

With the ability to free form functional parts from metals and polymers, 

Additive Manufacturing (AM) technology offers significant 

potential as a next-generation fabrication process. The 81m2 Additive/Digital 

Manufacturing Showcase at this year’s Austech has been 

specially developed to give visitors a real insight into the possibilities 

AM offers to both designers and manufacturers. It will also incorporate 

sit down areas for visitors to discover how this future capability 

can provide opportunities for their businesses. Static and live displays 

from leading exponents of this technology will highlight the latest developments, 

in addition to displaying examples of 3D printers, sample 

metal and polymer tools for investigation. 

“Additive manufacturing is a relatively new concept where fully 

functional components are manufactured directly from powder, ribbon 

or wire in a layered manner, by-passing conventional processes 

such as casting, forging, rolling, cutting, machining, welding, or 

drilling,” says Projects Coordinator, Creighton. “Components can be 

manufactured with highly complex internal, re-entrant features and 

undercuts - complexities that are unheard of in conventional manufacturing. 

AM also allows for significant part consolidation, which 

reduces tooling, assembly, maintenance, and inspection costs. Furthermore 

it has the potential to greatly reduce or even eliminate many 

stages of the traditional supply chain, reducing lead times, inventory, 

and supply chain transaction and logistics. 

“There are real opportunities to facilitate the further adoption of 

AM technologies in Australia to enhance business sophistication and 

improve manufacturing productivity. Australia has a rich heritage of 

manufacturing and is home to a number of world leading companies 

in sectors such as Automotive, Aerospace and Defence, Biomedical 

and Pharmaceutical.” 

About Austech 

AMTIL is the proud owner and organiser of Austech which runs in 

Melbourne and Sydney in alternate years and is generally scheduled 

for the month of May. Austech runs annually alongside National Manufacturing 

Week, making it the premier event of its type in Australia. 

To Pre-register and save time queuing at the door visit 

www.austechexpo.com.au and click on the link provided. 

Further information 

Kim Warren - Events Manager Phone: 03 9800 3666 

Email: kwarren@amtil.com.au Web: www.austechexpo.com.au 


29

Preview 

Austech, National Manufacturing Week, Ausplas 

24 - 27 May 2011 

The Melbourne Exhibition Centre, 

Melbourne, Victoria, Australia 

Dates and Times 

Tuesday 24th May 10am – 6pm 

Wednesday 25th May 10am – 6pm 

Thursday 26th May 10am – 8pm (late night) 

Friday 27th May 10am – 4pm 

Austech covers the key areas of machine tool and sheetmetal 

working including: 

• CNC Machining Centres: horizontal and vertical machining centres 

• Turning Machines: CNC lathes, automatic lathes 

Sheetmetal: forming, bending, punching, shearing equipment 

• Special Purpose Machines: grinding, broaching, boring, milling, 

waterjet cutters 

• Laser Equipment: laser profiling, laser cutting, marking and engraving 

• Ancillary equipment: cutting fluids, finishing, coatings, robots, CAD/ 

CAM software, cutting tools, hand tools 

• Precision manufacturers 

Latest developments in 3D scanning technologies for inspection and reverse engineering 

Hi-Tech Metrology, a leading Australian provider of metrology 

and scanning products and services, will be displaying the 

latest technology for 3D scanning, computer aided inspection 

and reverse engineering at Austech. 

Whether you use 3D scanning technology for design, 

analysis or inspection, this is the event not to be missed! With 

a focus on using the latest scanning technology to capture 

and process high resolution 3D spatial geometries for reverse 

engineering, visitors will walk away with practical knowledge 

and information on a complete range of laser scanning technologies 

that are available today, and gain an understanding 

of the key benefits that they can expect to achieve with 

the adoption of new technology in their day-to-day 

business operations. 

A combination of hands-on live demonstrations of 

the latest metrology equipment available today and 

interactive, problem-solving discussions will bring 

together industry professionals and the Hi-Tech Metrology 

team to give Australia’s manufacturers the best 

information available. 

On display will be 3D scanning technology from Hexagon 

Metrology, Romer, Brown & Sharpe, Sheffield, Leica, 

Kreon, Perceptron and Micro-Vu. According to David Eldridge, 

General Manager of Hi-Tech Metrology “we see 

the Austech show as a great opportunity to introduce the 

benefits and latest developments in 3D scanning technologies 

for inspection and reverse engineering to the 

Australian advanced manufacturing industry. We will 

show how these technologies help manufactures 

produce better designs, and get new products to 

market faster.” 

One of the highlights on display will be the 

Romer Absolute 7325SI in action, scanning a 

range of complex parts and components for reverse 

engineering and inspection tasks. The Romer 

Absolute SI scanning solution is the latest release product 

from Hexagon Metrology’s portable arm business, Romer Inc., and 

represents the latest development of a fully-integrated laser scanning 

system on the new Absolute series of portable measuring arms. 

“The integrated laser scanner technology is a milestone in the world 

of portable CMMs”, says Eldridge. “With the new system, our customers 

can easily achieve accurate and meaningful measurement results while 

benefiting from the Romer Absolute arm’s mobility and efficiency.” 

This unique completely integrated scanning package allows users to 

accurately measure and inspect parts to both part drawings and full 3D 

CAD models, as well as to collect vital 3D surface and positional data 

allowing users to create their own part models and designs in all of the 

latest 3D CAD packages. 

Other key equipment from Hi-Tech Metrology on show this 

year includes: 

Brown & Sharpe Global Performance 7107 CMM, measuring 

critical features on high-precision machined components – 

such as automotive engine blocks and cylinder heads, using 

the contact scanning functionality of a SP25M analogue probe 

for high speed, production-orientated inspection applications. 

This type of technology enables CMM operators to obtain the 

key dimensional data required in the most efficient and accurate 

manner – particularly of round or complex geometric 

features where traditional probing techniques prove to be inadequate. 

Sheffield Discovery D12 CMM with a Perceptron Scan- 

Shark laser scanner, being used to rapidly scan sheetmetal 

and composite material parts for inspection in the 

automotive and aerospace sectors. The use of laser 

scanning for complex shaped parts particularly in the 

automotive and aerospace sectors, is gaining widespread 

acceptance around the world as the best way 

to measure these types of components – efficiently 

and accurately. The Discovery cell will give visitors a 

first-hand experience into the world of non-contact laser 

scanning for inspection projects, and how this type 

of technology can enhance their productivity and improve 

measurement throughput. 

Romer Absolute 7325SE on a Brunson carbon-fibre lightweight 

tripod fitted with the recently released, latest technology 

laser scanner, the Zephyr II from Kreon Technologies designed for 

complex and difficult reverse engineering and inspection projects. The 

Romer Absolute SE series gives users the ability to specify and mount 

their own laser scanning system to the arm. The laser scanners can be 

from the entry-level Solano scanner from Kreon to the new Zephyr II 

product, capable of achieving scanning accuracies down to 15 micron, 

scanning rates of 500 Hz, and excellent for scanning difficult to scan 

items such as bright and shiny chrome and metallic parts etc. 

Other equipment being demonstrated on the Hi-Tech Metrology stand 

this year includes the very popular Vertex vision-based inspection system 

from US-manufacturer Micro-Vu which is excellent for measuring small 

and delicate parts, and has found many uses in the Australian market in 

the precision engineering, electronics, and plastic injection moulding sectors; 

as well as the newly released, and first Australian outing for the Leica 

AT401 laser tracker which has taken the European market by storm. The 

AT401 is the smallest and the most compact laser tracker on the market – 

yet still capable of measuring distances up to 160 metres with incredible 

accuracy and repeatability. 

Hi-Tech Metrology - Stand 687 

www.hitechmetrology.com.au 


Are you benefitting from a major Government 

initiative that supports manufacturing/you 

The initiative is Enterprise Connect 

A $50 million per annum Australian Government initiative 

aimed at delivering practical support to Australian 

manufacturing firms. 

AMTIL is one of 15 partner organisations that support 

this Initiative and is keen for both AMTIL members and 

non-members to benefit from this. 

Enterprise Connect delivers two main services: 

– a Business Review, delivered by a Business Adviser 

at no charge to the firm; and 

– Tailored Advisory Services funding up to $20,000 to 

help the firm implement improvements arising from the 

Business Review. 

To qualify 

• you possess an Australian Company Number (ACN) 

• you are a manufacturer 

• if located in Melbourne, Sydney, Adelaide, Perth or Brisbane - have revenue or expenditure of more than $2 million and 

revenue or expenditure under $100 million in the current financial year or one of the two preceding financial years 

• if located in a regional area, that is, outside the above cities - have revenue or expenditure of more than $1.5 million and 

revenue or expenditure under $100 million in the current financial year or one of the two preceding financial years 

If based in Melbourne: 

Call the AMTIL business adviser, 

Bruno Bello on 0409-123-701 

Email bbello@amtil.com.au 

Or go to www.enterpriseconnect.gov.au 


31

Preview 

High-speed spindles for milling, drilling, 

grinding or routing 

Air Turbine Technology will demonstrate its latest generation of precision 

high-speed spindles at Austech. A series of constant governed 

high-speed spindles with power up to 1.4HP for milling, drilling, grinding, 

and routing with no duty cycle will be on display and in operation 

to show reduced cycle times on CNC machines and turnkey automation 

systems that use small tools. 

Air Turbine Spindles TM patented solution is claimed to enable every 

CNC machine to operate at high speeds 24/7 and cut cycle times at affordable 

prices from $2000 to $5000. 

Automatically loaded Air Turbine Spindles TM upgrade CNCs for 

constant governed high-speed milling, drilling, pre machining, profiling 

and engraving in to your main spindle with ultra-low vibration and 

direct drive. 

With only two moving parts (governor controlled turbine and air 

cooled ceramic bearings) Air Turbine Spindles TM are precise and reliable 

with no maintenance, the company claims. 

Pictured: Air Turbine Spindles TM 650X CT40 with patent pending 

automatic tool changer option (TMA), milling an RC52 steel shoe 

mould, reducing production time by hours with a super finish at governed 

constant 40,000 rpm on a small frame 40 taper VMC. 

Air Turbine Tools, Inc. - Stand 570 

www.airturbinetools.com 

Superior surface protection 

From concept design and definition, to prototyping, 

right through to manufacturing, MiniFAB 

offers expertise at every stage of product development. 

At Austech, MiniFAB showcases its 

capabilities which are adaptable to a range of industries, 

from medical devices and diagnostics, 

to packaging and laboratory instrumentation. 

For complex structures that require a superior 

guard from outside environments, MiniFAB 

uses Parylene to provide maximum barrier protection. Besides the 

increased scratch resistivity, this optically clear coat reduces surface 

friction, is chemically resistant and inert. It is often used on circuit 

boards to help protect them from the harsh environments they are 

subjected to, but more importantly it provides a strong dielectric layer. 

“The greatest advantage of parylene is its adaptability,” explains Erol 

Harvey, CEO, MiniFAB. “It can provide a fully conformal, pinhole-free 

coating to a wide range of materials including polymers, silicon, metals, 

Quality all round 

Quality Machine Tools (QMT) will be exhibiting a wide range of high 

quality, precision machine tools at this year’s Austech show. These include 

the ‘Vantage MCY’ Multi-axis CNC slant bed lathe from its proven 

and popular range of Ace Designers. 

For the past 18 years, QMT have been the trusted suppliers of high 

quality conventional and CNC machine tools to the Australian manufacturing 

Industry. The machines have all been carefully sourced from 

highly reputable manufacturers around the world, complimenting the 

company’s mantra to provide precision machinery, backed by efficient 

after sales service and comprehensive training programmes. 

The range of products includes the ACE slant-bed and vertical CNC 

lathes, with up to 6-axis, which are available in 20 different sizes. Machining 

centres include: Ultra-fast drill tap machines, high-speed fiveface 

machines, and large double column machines with up to 10000 X 

5000 X 2000mm travel. CNC and conventional lathes are available with 

up to 2000mm swing and 12000mm between centres. 

QMT’s range further extends to 5-axis machines from Jyoti Huron, 

leaders in high precision 5-axis machines for the Aero Space, medical 

and precision engineering sectors. These 5-axis machines are offered 

in multiple configurations to suit any application. QMT also offer a 

range of Wire EDM machines up to 6 axis, EDM die-sinkers and cylindrical/surface 

grinders. 

Quality Machine Tools - Stand 784 

www.qualitymachinetools.com.au 

elastomers, paper and glass. This method 

ensures that no matter the object, the true 

angles and geometrics are preserved.” 

According to Harvey, using traditional 

coatings on medical components and diagnostic 

devices can be problematic, but 

parylene is ideal because its inert nature 

means that it is biocompatible, meeting 

USP Class VI requirements. It can also 

act as a lock-down, decreasing the risk of 

particulate contamination. “By adding a 

parylene layer you are protecting your medical device from damage, 

increasing its durability and prolonging its life,” he says. “The 

easy adaptability of parylene means that it can be used to coat almost 

any product in a time and cost efficient way, from the highly 

technical to the everyday components.” 

MiniFAB (AUST) Pty Ltd - Stand MS0 

www.minifab.com.au 


Performance Unequalled... 

with chatter-free milling 

Made from VHM-ULTRA, 

an Ultra Fine Grain Type 

of Carbide 

The Harmony range of endmills 

represents world’s latest technologies to 

provide increases in both performance 

and tool life. The key to successful milling 

is to minimise or eliminate the harmonic 

vibration produced in the cutting action. 

The Harmony Endmill overcomes 

vibration, through the latest technologies 

in tool engineering: 

Recessed for 

Longer Reach 

AICrN Coating for 

Longer Tool Life 

MICRO 

Optimised Edge 

Conditioning 

The Bottom Line for you: 

• Longer tool life 

• Improved surface finish 

• Increased productivity 

• Reduced production cost 

45º 

r 

45º Corner 

Chamfering 

(E535) 

Corner Radius 

(E559) Available 

Endteeth 

Gash for Edge 

Strength 

35/38º Unequal 

Flute Helix 

Visit us at 

Stand 555 

ENDMILLS 

for an on-site demonstration contact 

Sutton Tools on 1800 335 350 

100% Australian Owned 

www.sutton.com.au 


33

Preview 

Dimac Tooling: focus on 

productivity and the environment 

It’s all about productivity and the environment on Dimac Tooling’s 

stand at this year’s Austech. 

Among the company’s exhibits will be several recent additions 

to the company’s already impressive line-up of CNC machine 

tool accessories. Here are some of the new products, 

all designed to increase shops’ productivity and reduce the 

environmental impact of machining processes to a minimum: 

Coolant maintenance 

In order to deal with the huge amount of oil used and swarf 

produced during machining processes, Dimac offers a range 

of coolant maintenance products, which will be demonstrated 

on the company’s stand. 

“Machining coolant (or metalworking fluid) maintenance is 

still considered an art in many machine shops,” Dimac Director 

Paul Fowler says. “Smart users know that well maintained 

cutting fluids can last for years, not weeks or months.” 

Dimac offers the Zebra range of oil separation systems to 

skim up the surface oil coming from a machine’s lubrication system. 

The oil is skimmed on the belt, comes out of the unit into a gravity separator 

and is then returned at the back of the machine while the coolant 

is returned to the machine. The Zebra Oasis portable coalescer extends 

the life of your coolant and tooling and prevents shop mist or any health 

issues. “Keeping your coolant in a good condition can prolong the life 

of your coolant for up to three years,” Fowler concludes. “As a result, 

machine shops can save costs while at the same time increasing productivity 

and part quality.” 

Clean air workshops 

For clean and healthy air in workshops, Dimac showcases the Germanmade 

REVEN Recojet oil mist separators and Ultra Cleaners, highly efficient 

mechanical air filtering units using mechanical separating system 

X-CYCLONE. Air pollutants and contaminants from oil, emulsions and 

other fluids are separated from the ambient air as aerosols to a very 

high extent. This equipment dispenses with auxiliary energy supply as 

well as any auxiliary material (fabric, etc.). 

The units are particularly well-suited for the separation of harmful 

substances from the air including air pollutants in the form of aerosols, 

mist or vapour (saturated) as well as fine dust. These particles are conducted 

together with the transporting medium air into the X-CYCLONE 

separator by forced ventilation (fan). The collected fluids are returned to 

your equipment and your working environment is mist and particle free. 

High-pressure coolant 

Expanding Dimac’s line of versatile 

CNC machine accessories 

designed to improve productivity 

is the Cooljet high-pressure 

coolant system. “During the 

metal cutting processes, significant 

heat is generated at the tool 

and workpiece interface, primarily 

from the effects of friction, 

which can be detrimental to the 

tool and the workpiece,” Fowler 

explains. 

With the on-demand Cooljet 

coolant system cutting fluids are 

pumped to pressures of 1000psi 

(70 bar) or more, and are accurately 

directed to the cutting 

zone through an appropriate 

nozzle. The resultant jet stream 

of coolant is able to penetrate 

the high temperature cutting zone, delivering vital lubricants to the cut. 

“If you are targeting to reduce process cycle times, you will find that 

your tool life will be significantly extended, and the quality of the cut 

is considerably increased after applying high-pressure coolant. Its applications 

are extensive from drilling, grooving, boring, cutting of hard 

metals which have a high nickel content, to small tooling applications.” 

Quick Jaw Change 

Dimac will have a wide range of fixtures, vises and chucks on display, 

including the expanded range of the new Kitagawa DH Series Collet 

Chucks, now including the new DHP-42 (42mm diameter capacity) version, 

which will be available soon and joins the DHP pull back versions 

currently available. The DH Series is available with quick release gun 

and specialised collets and is the newest addition to the wide range of 

quick-release and standard collet chucks already available from Kitagawa. 

For efficiently changing chucks Dimac will demonstrate the Kitagawa 

QJR series (Quick Jaw Release), a quick change power chuck. 

Using a quick change base jaw system it can accept standard metric 

serrated top jaws from existing B200 and BB200 chucks. These base 

jaws can be changed quickly and easily using the hand-operated key. 

Dimac Tooling Pty Ltd - Stand 584 

www.dimac.com.au 

Laser 3D: modern laser cutting capabilities delivered on time 

Laser 3D will showcase the capabilities of their modern laser cutting machines 

at Austech. The company has established itself as a leader in the laser cutting 

industry by consistently delivering on time, quality laser cut components to its 

customers. They have achieved this by an ongoing investment in capital equipment 

and personnel. This is backed by an MRP system tailored to suit current and 

planned future capabilities. The company’s modern machines have the capability 

to laser cut flat or formed metal and plastic components as well as rotary cutting 

of round tubes and RHS. 

Manufacturing capabilities also include tapping, counter sinking, welding (mig/ 

tig) and folding by the installation of two CNC press brakes in the Melbourne plant. 

Laser 3D has manufacturing plants in Melbourne and Adelaide and a sales 

office in Sydney. 

Visit their stand at Austech and go in the running to win Hotlaps at Sandown 

driving a V8 Racecar. 

Laser 3D - Stand 523 

www.laser3d.com.au 


110531 MTIQualos_Half:Layout 2 13/4/11 1:10 PM Page 

Preview 

Haco exhibits innovative 

machinery to lead local 

manufacturers into 

the future 

It’s all about technology, productivity and quality at Haco Australia’s 

stand during this year’s Austech exhibition. Haco claims to offer a solution 

for every metalworking need and Austech visitors will see the 

diversity of the company’s enhanced sheetmetal working portfolio. 

Among the many machines on show, the company demonstrates 

the Haco CNC plasma machine KOMPAKT 3015 featuring a Hypertherm 

HyPerformance HPR XD plasma source, which is specifically designed 

to be mounted on X-Y cutting tables. “The highlight on this machine is 

our new APC59T Windows® control.” Managing Director Kurt Bossuyt 

explains. “The touch panel effectively reduces the number of keyboard 

and button actions to an absolute minimum, allowing the user a straight 

forward, intuitive control of the entire production cycle. 

The highly advanced software "RoboTorch" raises the bar for other 

plasma software on the market due to the simple layout of the userinterface. 

This allows direct access to the desired functions and as a 

result creating optimum operator convenience.” Bossuyt continues. 

“Our Automatic Arc Voltage System continuously adjusts the arc voltage 

for consumable wear and this results in correct torch height over 

the life of the consumables, without operator adjustment.” 

As Australia’s new exclusive agent of Bomar bandsaw products, the 

exhibit will also feature a range of Bomar bandsaws, including the wellknown 

Transverse model machine as well as the new line of Individual 

series machines. The Individual GANC model is an NC-controlled automatic 

band saw with a broad cutting range, a comfortable and simple 

handling and excellent cutting performance. The saw frame moves 

in tolerance-free pre-stressed linear guides. With a feeding length of 

750mm in one cycle, the machine is very precise, measuring the cut 

lengths with a high resolution linear measuring system. Bomar also offers 

the Individual DGANC model with a full CNC control providing automatic 

double mitre up to 60°, with a single hitch length up to 6000mm. 

Haco will also exhibit two models of its Multi range Kingsland steelworkers 

and two CNC pressbrakes. The ERM model is an entry-level 

press featuring a 2D graphical control and XR backgauge, while the topof-the-line 

model ERM features a 3D & 2D graphical control, a 6-axis 

backgauge and hydraulic top and bottom tool clamping. “This machine 

is a high-production machine,” Bossuyt says. “It is all about the software 

operating the machine.” 

Moreover, the new Haco Q5 turret punching machine is now available 

in Australia. With its 22 or 30-tons high-speed servo hydraulic 

punching head, rotation axis for all tools, and standard interpolation 

parameters, the Haco series Q5 is a flexible CNC turret punching machine 

aimed at improving shop’s productivity. The large fully-brushed 

sheet support tables together with the standard repositioning cylinders 

allow for the trouble-free processing of standard sheet size. Moreover, 

the machine features a user-friendly TPC69T graphics controller with 

an intuitive user interface designed to process simple or complex tasks. 

Haco Australia Pty Ltd - Stand 582 

www.hacoaustralia.com.au 


35

Preview 

Multi-use laser with drastic set-up 

time reduction. 

Amada will showcase its new Multi use laser 

machine F0M2 RI (Rotary Index) at Austech. 

Designed for manufactures whose main 

work is flat sheet, and value adding work 

is in pipe and structural steel processing, it 

enables processing both flat sheet and pipe 

or tube with a claimed drastic reduction in 

set-up time. 

Structural steel and pipe cutting: Defect free, high 

precision production can be proven through computer 

simulation prior to flat sheet metal & structural steel 

fabrication. This is done using Amada’s Sheetworks 

and Dr.Abe Tube software packages. 

This high-precision processing is claimed to decrease 

the further working time required prior to processes 

such as welding and assembly. Changeover time 

from sheet or plate cutting to pipe cutting is very short, merely 60 seconds 

Structural Steel Processing: Round pipe max diameter is 220mm and 

square pipe max size is 150mm. 

Repositioning function supports regular 6m pipe lengths. Support 

rollers keep the exact center of pipe in position, even coping with curved 

pipe lengths. 

The laser head operates near the support roller after centering. This 

unique feature aids achievement of high-precision machining. 

Cutting conditions for pipe cutting is the same as per flat sheet material; 

all the latest laser functions can be utilised in pipe cutting. 

Flat sheet cutting: Single lens cut and Automatic nozzle changer- The 

optimum beam controlled by AO (Adaptive optics) system generates 

best cutting condition from thin to thick material. 

7.5” focal lens enables processing from 1mm to 22mm of material 

thickness and eliminates set up time of changing focal lens. 

Automatic nozzle changer is achieved to reduce set up time of nozzle 

adjustment and realizes continual production over the full range of 

materials. 

Oil Shot- Spraying oil before piercing on materials. Oil shot brows 

away slug and achieves high quality cut with stable piercing. 

WACS (Water Assist Cutting System) is equipped with an adjustable 

water mist to absorb heat generated from cutting thick sheet metal. 

This feature stabilizes thick steel process and improves product quality, 

material utilization and reduces cut failures. 

Cut process monitoring system is equipped for saving pierce time 

and maintain stable cutting. 

Amada Oceania - Stand 560 

www.amada.com.au 

Fast, easy 3D printing features true “desktop” design 

3D printing is a relatively new and developing technology that can 

allow users to transform their 3D computer designs and drawings 

into solid objects. The main limitations for this industry has been 

the high cost of the printers and their bulky size. At Austech, Benson 

Machines will exhibit the BFB3000 3D printer, which is the next installment 

by Bits From Bytes that overcomes the limitations of high 

cost and bulk, and is a prime example of a true desktop 3D printer. 

The BFB3000 includes a large print area (up to 275x275x210), an 

object layer thickness of 0.1mm, a robust frame and an open design 

making it not only highly accurate but visually pleasing. The printer 

can be placed and run anywhere (with power) as it prints objects 

from an SD card and therefore is totally stand-alone. Furthermore, 

it is clean and quiet. 

This printer is designed for the perfect out-of-the-box experience 

including purpose written software to transform STL files into 

printed objects very quickly. The simple design and engineering of 

the BFB3000 enables any grade of user to setup and maintain the 

printer’s accuracy and integrity. The printer is electronically configured 

to accommodate up to three printheads allowing printer upgrades 

to be fast and hassle free, it is claimed. Additional heads 

enable users to use multiple materials types and different colours 

for printing. 

Benson Machines P/L - Stand 705 

www.bensonmachines.com 


SIX NEW ANGLES ON 

SQUARE SHOULDER MILLING. 

 

The insert can be indexed 2x3 times. Lower cost per 

cutting edge. 

 

Gives longer tool life. Diameter range: 40-160 mm. 

Available in three different pitches, coarse, 

normal and close pitch. 

° 

Saves time and money. No mismatch 

when machining walls in different 

steps. Achieve a true 90° square in 

one operation. Fewer tools and tool 

changes needed. 

 

Enables insert to be locked securely. 

The locking screw is placed in the same 

direction as the cutting forces. 

 

Wiper flats on the insert for better surface finish. 

 

ME09 for stainless steel; M13 for steel and cast iron; 

MD15 for harder materials and higher cutting speeds. 

SQUARE 6 

 

www.secotools.com 

Ph 1300 55 7326 Fax 1300 65 7326 E-Mail secotool@secotools.com 


37

Preview 

Idronic showcases job shop software for 

production control operations 

Australian specialist metal fabrication software company Idronic will 

demonstrate its innovative management system software LaserQuote 

at Austech. 

“Accurate information about how your business is performing is important 

at any time, but in difficult times, it is absolutely essential,” says 

Managing Director Codrin Mitin. “Getting the right information to the 

right person at the right time has never been more critical to your business. 

Finding the right solution that can bring insight into your business 

and continuously improves your profits is a must.” 

LaserQuote is a business management system software designed to 

manage and streamline all daily business activities for fabricators, profile 

cutters, engineering and sheet metal shops. LaserQuote enables parts 

programming, customer relations, quote generation, as well as production 

control of various features in metal cutting and fabrication operations. 

“LaserQuote is the culmination of countless testing and adjustments 

to business procedures and methods specific to the contract cutting and 

sheet metal industries,” Codrin explains. “Our team has a wealth of experience 

and comprises of former metal business owners, Java and Mysql 

programmers and web developers. For more than 15 years we have constantly 

been tapping into the experience of many metal fabrication shops 

and with their assistance and advice we developed LaserQuote.” 

Because LaserQuote has been built from the ground up to be used as 

a metal fabrication software, the built-in laser cutting wizard can generate 

an accurate and consistent quote in seconds, not minutes. The wizard 

reduces the process of determining the cost of a given part. In addition, 

it provides screens required as per the user input. The software 

facilitates the automation and creation of programming where multiple 

parts obtained from clients are nested together using your CAD nesting 

software. This results in achieving high efficiencies of material usage. 

Moreover, the profile cutting software determines the availability of 

the subsequent machine relating to the job. By utilising an online customer 

interface, clients can access the production stage of the jobs. 

Customers can view the full time-stamped status along with a digitally 

recorded signature. In addition, by using the wizard consumers can 

request online quotes for parts. 

Why LaserQuote 

Do you know which jobs are making you money and if yes how much 

Do you really appreciate the cost factor involved in the quotation process 

Are you making the most of your synergy when it comes to maximising 

material allocations Is your inventory linked and audited to 

your jobs Is scheduling resources still done in Excel Is your data 

access secure 

If you cannot answer all of these questions with a definite “Yes”, 

then you should consider the Idronic business management software, 

which is all about speed and efficiency to maximise your business’ 

profits. More quotes, faster quotes, accurate quotes mean more orders 

and more profit. Customers using LaserQuote report up to 80% win 

rate on quotes and can average 60-70 quotes per day. A typical laser 

cutting job shop running 24/7 with three lasers can cope with only one 

estimator. 

Features include: 

• CRM – Full customer communication via email, letters, faxes, alerts 

and a system-wide history of all activities 

• Quotes and parts – catering for simple parts and complex assemblies 

• Jobs and customer orders 

• Production data collection via terminal or barcode for both shopfloor 

and office use 

• Programming – automate the profile cutting aspect and improve efficiency 

• Suppliers, materials, purchase orders and inventory – fully audited 

raw material and spare parts movement allows for keeping track of 

which material has been used for which job 

• Equipment – keep track of all the consumables and maintenance 

matters for all of your equipment 

• Reports – create reports from all sections of the system including 

jobs, quotes, customer orders or sales 

Idronic Pty Ltd - Stand 693 

www.idronic.com 

Acra shows Durma 4kw Laser machine and 

press brake 

Acra Machinery will be showcasing a select range of the company’s vast range of 

machinery at Austech. Acra Machinery is an Australian-owned and operated company 

established in 1977, selling, servicing and repairing sheetmetal machinery from 

numerous suppliers around the world. The company specialises in the supply and 

service of a range of equipment from the world’s leading manufacturers including 

Durma, Jorns AG and Euram. On show will be a Durma 4kw laser machine, a Durma 

pressbrake, guillotine, punch & shear, Durma section rolls, corrugated curving rolls 

and the Jorns Eco-TwinMatic. The full range of controllers from CNC, NC and standard 

controls are all available upon request with Acra’s machines. Custom applications 

ranging from small to large scale have been our specialty over the years and welcome 

all enquires. 

Acra Machinery Pty Ltd - Stands 515 and 558 

www.acra.com.au 


AUSTECH 2011 

24th – 27th May 2011 

Austech Hall, Booth: 642 

± 120° 

± 120° 

ø 840 mm 

Height 500 mm 

monoBLOCK ® 

NEXT GENERATION – Redefining 

5-axis milling with a swivel rotary table 

_ _ _ _ _ _ _ _ Whether for 5-axis simultaneous machining, highly dynamic 

high-speed milling, high-torque performance cutting, or for volume parts 

production on 3 to 5 axes, the DMU 65 monoBLOCK ® provides precision, 

performance and productivity for all applications without compromise. The 

DMU 65 monoBLOCK ® is the COMPREHENSIVE solution for all industries. 

HIGHLIGHTS DMU 65 monoBLOCK ® 

_ Large work space capable of holding work pieces that 

are up to ø 840 mm wide, 500 mm high and 1,000 kg in 

weight with the swivel rotary table. Alternatively, work 

pieces up to 1,000 × 840 × 560 mm and 1,800 kg can be 

processed on the rigid table. 

_ Stainless steel work space retains machine value 

_ Crane loading from above over the table centre (standard) 

_ Open door and accessibility: 

_ Door opening 1,430 mm 

_ Front tool loading during production 

_ Fully accessible from the front, even with automation 

_ Smallest foot print (7,5 m²) 

All DMG/ MORISEIKI news is available online at: www.dmgmoriseiki.com 

DMG / MORI SEIKI Australia: 

Melbourne Head Office 

Unit 6, 6 Garden Road, Clayton VIC 3168, Australia, Tel.: +61 3 8545 0900, Fax: +61 3 9561 4999 

Sydney Office: Tel.: +61 2 8844 9700, Fax: +61 2 9638 6111 

If your mobile phone is equipped with QR code recognition software, you will have direct access to our homepage. 

Authorized DMG / MORI SEKI Dealers in Australia: 

Qumac Engineering Services – Queensland, Tel: +61 7 5547 5066 / HS CNC Machines – Victoria, Tel: +61 3 9763 8207 Australian / Harris Manufacturing Machine Tools Technology – Western Australia, May 2011 Tel: +61 8 9574 6951 

39

Preview 

Laser marking and welding technology for flexible industrial workplace applications 

A leading Australian laser machines and equipment supplier, 

M2 Lasers, will demonstrate its extensive range 

of laser cutting, marking and welding solutions to the 

manufacturing industry at Austech. The company will exhibit 

four innovative industrial laser devices, including the 

popular ALV 100 compact multifunctional laser welder, as 

well as the German-made ACI laser marker, which is 

used for fast, quality, permanent laser marking of 

metals and plastics. 

Laser marking 

The ACI WorkstationPROFESSIONAL laser marker 

is designed for larger workpieces and batch runs 

for the efficient and easy in-house marking of serial 

numbers, bar codes, datamatrix, text or logos. 

Designed to be a manual workstation with an automatic 

door opening unit, it allows marking of 

individual parts and small series of parts. With 

its 600mm x 600mm, the T-slot base plate in the 

extended working area provides extra large space 

for bigger parts, as well as the option to add rotation 

modules to mark cylindrical parts. An x-axis 

extending the working area to 500mm is installed as 

standard, offering a freely programmable marking area of 

max. 500mm x 180mm. A motorised z-axis can automatically adjust 

the lasers height for varying part heights. 

According to M2 Lasers General Manager Neil Penman, laser marking 

is mostly used as a way of permanently marking an item for tracking 

its security and quality, “but it is also a technique that enhances the 

monetary and esthetical value of products by making them look more 

eye-catching and easily visible.” 

“Rather than using a vibrating or rotating tool to engrave a mark on 

the products, a high-powered laser offers high-speed marking, excellent 

repeatability while minimising the impact on the environment, since 

laser marking makes no use of inks or solvents,” he says. 

Laser welding 

The ALV 100 laser welder on show during 

Austech is ideal for precision welding of metals in 

the tool and die industry, sensor production and 

medical device manufacturing. 

“During the last decade a number of laser 

manufacturers in Europe and the US have started 

producing laser welders, which are designed for 

specific industries and applications, which has 

made the technology more affordable and userfriendly, 

and therefore contributed to a wider up 

take of the technology in Australia,” Penman 

says. “Laser welding can give you precise control 

of the energy you deliver to a weld. It is this 

controllability, speed and localised heating which 

allows a laser to successfully weld materials with 

high melting points or high conductivity. Most applications 

of lasers are therefore based around jobs 

that require strong welds, repeatable results, noncontact, 

precision, process control, small heataffected-zone 

or welding complex alloys e.g. 

titanium and stainless steel.” 

The ALV laser welder can be individually equipped 

for manual welding of one-off parts, semi-automatic welding for batch production 

and fully automatic welding for volume production. The four-axis 

motion system enables controlled movement of workpieces up to 50kg in 

the working chamber, using either the joystick or automatic control. In addition, 

the worktable’s large vertical travel enables processing of larger tools 

and moulds. 

The compact laser device fulfils the requirements of laser class 1, 

since the welding process takes place in an enclosed working chamber. 

Thus the device can be set up in any workspace. 

M2 Lasers Pty Ltd - Stand 646 

www.m2lasers.com.au 

Solutions for the processing of 

everyday materials 

Biesse Group, a leading provider of innovative technological 

solutions for forty years, invites Austech visitors to investigate 

its range of CNC machining centres, which can be designed for 

one purpose or many. On show at Austech, the Biesse Group’s 

Klever Series by Biesse, a CNC solution that delivers manufacturers 

of everyday materials a flat table machining workcentre 

solution. The Klever’s wide range of sizes give manufacturers 

the flexibility to select the solution which is best suited for their 

factory the different materials to be processed. With software 

included for sign writing and lettering, this is will be one of the 

best value machines at Austech, the exhibitor claims. 

Also on show will be the Intermac waterjet cutting centre series, 

a machining solution that is able to cut tough materials and 

intricate patterns with precision and accuracy, Biesse claims, 

providing users with an outstanding finished product. According 

to Biesse, this simple to operate machine not only saves its 

owners money by reducing waste material, it is also claimed 

to be very flexible and comes with BiesseSoft, an easy-to-use 

software solution. 

Biesse Group Australia - Stand 742 

www.biesseaustralia.com.au 


www.kraas-lachmann.com 

Tiger·tec ® Silver is the new highperformance 

miracle tool for steel 

and cast-iron milling from Walter. 

Extremely tough, extremely hard and 

extremely long-wearing, it improves 

performance by up to 100%. 

The machining age is over. 

It’s time to Tiger. 

Competitor 

Tiger·tec ® 

New Tiger, 

new benchmark: 

up 

to 

100% 

performance 

increase 

Tiger·tec ® Silver 

Walter Australia Pty. Ltd. 

Hallam, Victoria 

+61-3-8793 1000 

service.au@walter-tools.com 



41

Preview 

Hi-tech, multi-axis CNC lathes & 

machining centres 

Hare & Forbes Machinery House’s display at AUSTECH 2011 has a 

hi-tech theme with multi-axis CNC lathes & machining centres from 

Doosan Infracore Machine Tools & Hartford “The Machining Centre 

Company”. 

New release products from Doosan Infracore: 

Doosan Puma 2100, 2600, 3100 Series 

The NEW Doosan Puma 4 digit series, on display at AUSTEC 2011 is 

widely acclaimed as the next generation of high performance turning 

centres, with greatly improved performance, reliability, and usability 

through the utilisation of the latest technology, Hare & Forbes claims. 

The series caters for a full line-up including 2-axis, 3-axis & Y-axis 

models all with optional sub-spindle. 

Doosan Mynx 5400, 6500, 7500 Series 

According to the exhibitor, the Mynx 4 digit series is designed to offer 

exceptionally high rigidity utilising the ultra-heavy duty Box Type guideways. 

The powerful spindles form the basis for heavy duty machining 

capability which is claimed to perform even in the most demanding 

applications. 

Vertical turning centre for ultra large and heavy duty cutting 

The new VTC models from Doosan are proving their performance on 

the global stage, with tooling mounted on a rigid ram with a taper type 

tool clamping system for a claimed high reliability and rigidity. The 

enormous spindle power, combined with large sized highly rigid cross 

roller bearings used in the table provides superior cutting ability and 

massive metal removal rates for the largest workpieces up to 6m diameter 

and 60T in weight. 

High-precision Swiss type turning centre 

Enhanced productivity and ultra-high speed is obtained through innovation 

and determination. With applied technology such as a servo driven 

collet mechanism, electronic synchronisation between the spindle and 

guide bush and a powerful built-in high torque motor makes this sliding 

head machine design an innovative leader, Hare & Forbes claims. 

New release products from Hartford: 

Horizontal boring machine 

World-class precision boring machines with outstanding standard features, 

impressive gearbox spindle drive power, torque output and machine 

accuracy. Featuring 4-step gear-drive spindle head, torque output 

of up to 2,312 Nm, linear guided W-axis with 500 mm travel. 

LG-1370 + low inertia motor 

With a specially designed low inertia spindle motor the LG-1370 is said 

to be capable of increasing tapping efficiency while saving precious 

time. General specifications are working surface of 1,400 x 650 mm 

and table load of 1,000 kg. Travels are longitudinal travel (X-axis) of 

1,300 mm, gross travel (Y-axis) of 700 mm and vertical travel (Z-axis) 

of 650 mm. Aimed for the production market and excellent for LCD, LED 

and other high tolerance, volume production. 

USC ultrasonic spindle machining centre 

The USC ultrasonic spindle machining centre features an ultrasonic 

spindle for solid fragile material. The machine is ideal for machining 

glass panels similar to iPhone / iPad screens and optical lens. Other 

market areas are jewellery, medical equipment, aviation and extra-hard 

machining. 

S-Plus 10 production centre 

The S-Plus 10 is a performance upgrade from the popular Hartford F1 

Series. Featuring direct drive spindle as standard with enlarged spindle 

diameter, ball screw and linear guide size upgrade. The S-Plus 10 is 

designed to enhance accuracy and efficiency for production. 

Hare & Forbes Machineryhouse Pty Ltd - Stand 602 

www.cncmachine.com.au 

Precision grinding technology 

Winterthur Technology exhibits precision grinding technology for all applications 

from leading manufacturers of super-abrasives and grinding machine 

tools at this year’s Austech exhibition. The company highlights its commitment 

to its global presence by the opening of Winterthur Technology Australia in 

July 2010 to ensure continued supply and support to the Australian and Asian 

market. 

The Winterthur Technology Group is one of Europe’s three leading manufacturers 

of bonded abrasives for industrial applications. The 14 production sites 

of the Winterthur Technology Group have sufficient capacities to play a decisive 

role on a global scale in their area of activity, the company claims. The most important 

users of the Group’s abrasives are the automotive, aerospace, machine 

tool, glass, automotive tool and steel-making industries. 

“Research and development activities at the Winterthur Technologies Group 

are focused on application solutions geared towards individual customer 

needs,” says Guy Langmaid, Managing Directo.” Numerous patents and prizes 

document the Group’s technological leadership and innovative capability. Products 

younger than three years generate about one third of sales.” 

Winterthur Technology Australia Pty Ltd - Stand 725 

www.winterthurtechnology.com.au 


Preview 

Business expansion to deliver 

advanced solutions 

Bennett Precision Tooling Pty Ltd (BPT) is looking forward to exhibiting 

at Austech. “We are excited about our recent expansion with 

opening of a second toolmaking site in Sydney plus a customer 

service centre in Singapore,” comments Mark Bennett. Since being 

established by Bennett in 1981, the company has always focused 

on delivering advanced technology solutions to its customers. “We 

are now employing over 40 skilled staff in Sydney, plus three toolmakers 

in Singapore to support our customers in that region. BPT 

has extensive experience dealing in world markets and is able to 

compete effectively in both Europe and Asia.” 

BPT offers design and Manufacture of: 

• Thermoplastic Injection Moulds 

• LSR Injection Moulds (single and multi - cavity) 

• All facets of Automation including robot End of Arm Tooling, 

designed, manufactured and tested in-house. 

• Micro-Precision CNC Machining and Grinding 

• Precision Press Tools 

• Product development 

According to the exhibitor, the recent expansion has further 

enhanced BPT’s ability to offer competitive delivery even on large 

projects with world’s best technology including nine CNC milling 

machines, CNC lathes with live tooling, CNC wire and Ram EDM, a 

fully equipped metrology lab with both CMM and optical measurement 

capability. 

Bennett Precision Tooling Pty Ltd - Stand MS2 

www.bptooling.com.au 

Auto-index turret punch with 

integrated part chute 

Euromac Australia will be demonstrating 

some of the wide range of highquality 

Italian-made Euromac metalworking 

machines. Euromac has been 

manufacturing metal working machinery 

for over 25 years. Among other 

displays, Euromac demonstrates the 

Euromac MTX Flex12, 1250/30-2500 

auto-index turret punch with integrated 

part chute. Some of the machine’s main 

features are the ability to process a full size 1250mm x 2500mm sheet 

in a single pass with auto repositioning for larger sheet sizes, 6mm material 

thickness even when using multitools, punching speeds up to 375 

hits/min at 20mm centres, nibbling speeds up to 1000 hits/min, tool capacity 

up to 66 tools with up to 18 being fully indexable, 350 x 350mm 

part chute and peak power consumption of just 8.5kw (10kva/20.5a). 

On-Machine Verification reduces 

inspection times 

Camplex will demonstrate the latest release of PowerINSPECT OMV 

(On-Machine Verification) at this year’s Austech show. According to 

Camplex, PowerINSPECT OMV offers machine shops the opportunity 

to slash setup and breakdown times, as well as giving absolute confidence 

in a completed part before it is taken off the machining centre. 

With modern machine tools using high accuracy measurement feedback 

systems, and when combined with accurate probing systems and 

PowerINSPECT OMV software, this allows the machine tool to be used 

as a very versatile measurement device. 

A measurement sequence is generated within PowerINSPECT OMV, 

which is then run on the machining centre. Instant visual feedback is 

available, showing the tolerance at each point, as well as a verification 

report for download and distribution. PowerINSPECT OMV is claimed 

to significantly reduce inspection time as it can remove the need to 

transfer a part from a machining centre, to a metrology centre, and 

back again if re-work is required. "PowerINSPECT OMV is an exciting 

product as it increases the value of any machining centre with very little 

additional investment," says Fred Carlstrom, Managing Director of 

Camplex. "The machine shop can give their customer the part, as well 

as an inspection report validating their quality, and this can only work 

to benefit the supplier-customer relationship". 

PowerINSPECT OMV is available on a wide range of 3- and 5-axis 

machining centres, machine tool controllers, as well as supporting a 

range of new, and existing probe types. 

Camplex Pty Ltd - Stand 672 

www.camplex.com.au 

Euromac will also have the new Euromac 

Digibend 400 horizontal bending 

machine on display. According to Euromac, 

the range of Digibend machines 

allows for heavier flat bar stock, solid 

round bar and heavy walled pipe to be 

easily processed. These machines are 

perfectly suited to the electrical switchboard 

industry for processing copper 

bus bars, but will easily bend mild steel 

flat bar up to 200 x 25mm plus a wide 

range of other materials. Each different 

bend sequence or program can be easily 

stored and recalled. The optional CNC back gauge is controlled by the 

main controller and is perfect for production runs or parts with multiple 

bends. 

Euromac Australia Pty Ltd - Stand 670 

www.euromac.com 


43

Preview 

Additive manufacturing with Tasman Machinery 

Tasman Machinery will be exhibiting two of the 

world’s leading additive manufacturing systems 

from Stratasys at this year’s Austech. 

“Additive Manufacturing” is fast becoming the 

buzz word in tool rooms and manufacturing operations 

throughout the world. Traditional methods of 

design implementation, manufacturing and CNC 

machining are being replaced with “Additive Manufacturing” 

systems in companies the world over. 

Tasman Machinery will be exhibiting a Fortus 

400mc. The Fortus machines utilise fused deposition 

modelling (FDM) technology to build parts 

from a full range of plastic materials. 

On the one machine a customer can build prototypes, 

manufacture a full range of jigs and tooling, 

and produce end user parts. All at reduced costs 

and at hugely reduced time frames. It is not uncommon 

for users to reduce lead times from months to 

days, or weeks to hours, compared to their traditional 

methods of manufacture. 

A full range of plastics can be processed on the Fortus machines, 

including ABS, polycarbonate, medical grade plastics, and highly engineered 

plastics such as chemically resistant polysolfone and ULTEM 

9085, an exotic plastic, approved for use in the aerospace industry due 

to its non-toxic, smoke or burn properties when exposed to heat. 

Also on display will be the highly popular range 

of Dimension 3D printers from Stratasys. Dimension 

3D Printers are the most popular 3D Printer 

on the market. 

Due to their low price, ease of use, office 

friendly set up and use of real ABS plastic, the 

Dimension Printers are used by an ever growing 

number of organizations, from schools, universities, 

research houses, Govt departments and private 

companies to bring new ideas and products 

to market. 

Tasman Machinery is also exhibiting in the 

Ausplas exhibition, showing a high speed all electric 

injection moulding machine running in conjunction 

with a high speed takeout robot. 

Tasman Machinery - Stand 783 

www.tasmanmachinery.com.au 

Swinburne Uni recognises and responds 

to engineering skills shortages 

Swinburne University of Technology has recently recognised the 

need to align themselves with industry demands and recognise 

that to address the current skills shortages review the programs 

that they offer and add to this by increasing the programs on offer. 

A response to this in 2011 is to once again offer training for 

apprentices in the welding and fabrication trades with the establishment 

a new group of student apprentices early in 2011. 

Manager Craig Brittle, is aware that to meet future needs of 

Industry training providers need to be responsive and not as in the 

past reactive. "There is a need to recognise the continual changes 

that are driving the industry sector and respond to these in a timely 

and strategic manner which provides flexibility to the workforce 

and builds capability within organisations". 

We are also establishing an Industry Board to help influence 

and inform our strategic direction and are looking at working with 

organisations to increase the provision of Recognition of Prior 

Learning (RPL) to enable them to increase capability and sustainability 

in the workforce. 

A prime example of this is that we recognised the need to 

provide training for apprentices in the fabrication and welding disciplines 

said Brittle and therefore responded accordingly with the 

establishment and design of a program to accommodate industry 

needs and address skills shortages for the future. 

In addition to this, other programs that have been reviewed 

and redesigned are the Pre-Apprenticeship programs to provide 

students with directly transferable skills into the workforce and 

apprenticeships. Brittle expressed that Industry engagement for 

us is of high priority. 

Should anyone wish to make direct contact regarding this or 

any other related training issues they may directly contact him on 

03 9210 1243. 

Swinburne University of Technology - Stand 654 

www.swinburne.edu.au 

Three Australian premieres at DMG / 

MORI SEIKI Australia stand 

For the second time DMG / MORI SEIKI Australia is hosting a joint 

stand. At this year’s Austech, they will be featuring four machines 

at their own stand and two at partner stands. Highlights include the 

three Australian premieres: the newly developed DMU 65 mono- 

BLOCK® offering the entry into the high-tech world of simultaneous 

machining in 5 axes, the recently launched NTX2000 high-precision, 

high-efficiency integrated mill turn centre from Mori Seiki 

and the NLX2500, the first model to be released from the new X- 

Class series – a CNC lathe packed with extensive features including 

high rigidity, measures against thermal displacement, energy 

saving, space saving, MAPPS IV + ESPRIT, and compliance with 

safety standards. Furthermore at AUSTECH you can experience 

the travelling column milling centre DMF 180, as well as the DMU 

50 eco and DMU 70. 

With the German influence from DMG which is known for their 

innovative technology and Mori Seiki as a Japanese company 

known for reliability, DMG / MORI SEIKI Australia has the strength 

of two strong hands. A consistent market orientation on all industries 

and the technological leadership of the products are their key 

to success. 

DMG/ MORI SEIKI - Stand 642 

www.dmgmoriseiki.com.au 


607 


45

Preview 

One-stop CAD/CAM shop 

CAD systems demonstrated by STS-Camtek, a 

“one-stop CAD/CAM shop”, range from simple 

2D drafting up to the most complex 3D solids 

and surface modelling with integrated drafting. 

CAD products on display include: KeyCreator 

V10, VISI V19 and PEPS V8. According to 

the exhibitor, almost every CAM requirement 

can be accommodated by STS-Camtek solutions. 

CAM systems on display range from 

simple 2D mill, lathe, wire, plasma, laser cutting, through 2.5, 3, 4 

and 5-axis milling, 5-axis pentacut & 6-axis tubecut laser. 

Products on display are: KeyCreator V10, VISI 19, NCG-CAM 10, 

PEPS V8 and CIMCO V6. 

CAD / CAM Solutions: 

• KeyCreator 2011, true explicit & hybrid CAD modelling and drafting 

tool VISI 19 CAD & Machining: VISI is a fully integrated suite 

of CAD / CAM products. VISI’s range of CAD is extensive and 

CAM functions include 2 to 5-axis continuous milling and 2 – 

4-axis wire cutting 

• NCG CAM 10 is the easiest to learn CAM product available. NCG 

CAM 10 offers the full range of milling functions from 2.5 axis, 

3+2 axis to 5 axis continuous machining. 

• PEPS V8: PEPS offers a comprehensive range of CAM products 

including mill, lathe, wire, laser, punch and routing. PEPS also 

TXM demonstrates lean manufacturing 

solutions 

Due to popular demand for its lean manufacturing demonstration at 

last year’s Austech, leading Australian Lean Manufacturing and Project 

Management company TXM has committed to once again take its lean 

manufacturing solutions to Austech 2011. TXM’s stand will be themed 

as a "mini factory", demonstrating how lean manufacturing techniques 

can help advanced manufacturers become more agile. 

Over the past 20 years Lean techniques have been used as an effective 

tool for improving manufacturing competitiveness through reducing 

costs. However, in a globalised market, cost reduction is reaching 

its limits. In many cases the labour cost advantage of low cost countries 

is simply too great to be bridged. As a result many of the best 

Lean companies in Australia, particularly in the automotive sector have 

faced poor financial performance and closure. The focus for operational 

improvement therefore needs to shift from reducing cost to increasing 

value for customers. 

“Modern consumers want choice and service,” TXM Principal Tim 

McLean explains. “What this translates to for manufacturers is more 

models, shorter life cycles, greater customisation, and prompt product 

engineering. Agility or Agile Manufacturing means designing your 

process to be able to achieve this, reduce your lead times and remain 

competitive. ” 

The “mini factory” will feature real examples of some of the tools 

and techniques TXM uses to achieve 

• shorter lead times and a better and more flexible service to customers, 

• reduced working capital to free up cash, 

• changed workplace culture with all employees engaged in improving 

quality, productivity and customer service, 

• differentiation on service and a competitive edge to compete more 

effectively with imports, and 

• reduced costs. 

“At TXM we are manufacturing people first, consultants second,” 

McLean says. “I believe it’s vital to keep up to date with what’s happening 

in our industry. Austech offers the perfect platform to connect with 

industry professionals to find out their needs and help them achieve 

their business goals through utilising lean manufacturing. We can support 

manufacturers improve operational and supply chain performance 

and provide project management support for major change projects.” 

“We engage the whole workforce in improving the business and 

work to create a culture of continuous improvement in our customers' 

businesses, where everyone from the CEO down works together to improve 

operational performance and solve problems every day.” 

Take the first step towards achieving your business goals by visiting 

TXM’s stand during Australia’s premier manufacturing show and find 

out how to 

• increase productivity by 40% 

• reduce inventory by over 50% 

• slash lead times by 75% 

• space saving of up to 50% 

• transform your culture 

TXM’s skilled project managers can take the pain and risk out of 

major operational projects, including relocation, outsourcing, consolidation 

and technology implementation. 

TXM Lean Solutions Pty Ltd - Australia - Stand 505 

www.txm.com.au 

includes powerful 5-axis laser and 6 axis 

tube cutting. 

• CIMCO V6 Professional Editor & DNC-Max 

“MILL EXPERT” Solutions: 

A specialty of STS-Camtek is the development 

of knowledge based Expert CAM solutions for 

a variety of applications. Once customised to 

suit your particular industry needs, you simply 

introduce the job, (create or import a 3D 

CAD model), then select “Machine All”. – All machine programming 

including: selection of cutting tools, cutting strategies, operation 

sequencing, speeds & feeds and post processing are performed 

automatically with maximum efficiency. 

Our EXPERT CAM applications include: Mill Expert, Manifold Expert 

and Cabinet Expert. 

CAD/CAM Services: 

STS-Camtek provides a range of specialised technical services for 

industry. These include: CAD/CAM training programs, Reverse Engineering 

using a Faro Arm directly linked to Cadkey/KeyCreator, 3D 

solid modelling from reverse engineered data, mechanical design & 

detail drafting and NC programming. 

STS Camtek Pty Ltd - Stand 690 

www.sts.com.au 


Preview 

Rapid Concepts – Zcorp 3D eco- friendly 

printers 

Rapid Concepts has been a leading 

Partner of ZCorporation for a 

number of years selling their 3D 

printers to both commercial and 

education customers throughout 

Australia and more recently 

New Zealand. At Austech, Rapid 

Concepts will display the ZPrinter 

450. According to the company, 

3D printers are an important 

training tool in education and the 

most successful companies have 

adopted 3D printing as a critical 

part of their design process. 

ZCorp printers are said to be the only full colour 3D printers available. 

The printers produce physical colour models quickly, easily and 

inexpensively from CAD and other digital data costing one-fifth the cost 

of other technologies, the exhibitor claims. The printers are unique as 

all unused material is recycled for the next build eliminating waste, and 

with no physical support structures required to build the parts, no dangerous 

cutting tools or toxic chemicals are needed. The printers are 

quiet, odour free and are eco-friendly. 

The latest generation of printers has been designed for ease of use 

with the printers performing most operations automatically. With automated 

powder loading and recycling, snap-in binder cartridges, control 

panel for easy operation, and 5x-10x faster than all other technologies, 

the printers are an essential tool for today’s market. 

The printers are based on off-the-shelf HP inkjet technology. Printing 

a part begins by opening a CAD file in the ZPrint software. The 

software enables a view of the printers build chamber in three dimensions 

and provides the ability to zoom, rotate and pan objects in the 

entire build area. The software allows the user to rotate, scale and make 

multiple copies of a file or import several different files to be printed simultaneously. 

You can 3D print text labels, logos, design comments or 

images directly onto the model and with a full 24-bit colour, the printer 

is capable of producing thousands of distinct colours. 

Rapid Concepts Pty Ltd - Stand 691 

www.rapidconcepts.com.au 

Comprehensive CAD/CAM tools 

Once again, manufacturers 

will be able to have an experience 

of some of the most 

functional and efficient CAM 

tools available in today’s world 

of manufacturing. With 31 

years of expertise in production 

and distribution of CAD/ 

CAM systems, NC Computer 

Systems (NCCS) will be showcasing 

its manufacturing solutions during Austech. 

MetaCAM is the new frontier in the sheet metal CAD/CAM world 

and is currently the most comprehensive end-to-end solution, NCCS 

claims. According to the exhibitor, MetaCAM boasts a consistent user 

interface and seamless integration of all modules enables users to catalyse 

high productivity and shorten the learning curve in diverse industrial 

sectors. 

What’s New in MetaCAM V.8 

• A new and improved layout table sequencer 

• Improved speed of simulation of the Bending machines 

• Dock command computes the beam width and uses it automatically 

• New chain cutting and bridge feature supported for Waterjet machines. 

• Improved behaviour of manual nesting of common line 

• “Slice the skeleton” feature is now included in table sequencing 

• Support offline programming of welding robots 

CAMWorks is an intuitive feature-based CAM solution uses best-inclass 

technologies and adaptable automation tools to maximize machining 

efficiencies and simple to use. 

New features include: 

• Roughing – Ideal for prismatic parts 

• Machining complex parts - Create tool paths across complex spheres 

that cannot be machined on 3-axis machines. 

• Automatically identifying machining areas 

• Improved feature recognition and decreasing computation times by 

more than 50% over previous CAMWorks versions. 

NC Computer Systems - Stand 631 

www.nccs.com.au 

Realtek 


“Accurate, quick, 

very reliable, 

excellent 

response time on 

support from 

Realtek.” 

Frank, Hargo 

Engineering 



“Why do 95% of Australian sliding head buyers choose Star” 

“Being backed by STAR’s 

longest serving agent of 23 

years, Realtek offer 

outstanding support and 

product knowledge. It gives 

us the edge.” 

Warren, Yann Engineering 

“Price, quality, reliability, 

technical support, easy to 

set and program.” 

Ron and Richie, APT 



3081 

T> 03 9457 6377 

F> 03 9459 4695 


WE HAVE STARS ON OUR TEAM 

47

Preview 

Sheetmetal Machinery Australia 

exhibits CENTURIO 

At this year’s show, Sheetmetal Machinery Australia will be offering 

visitors the opportunity to view live demonstrations of sheetmetal 

and fabrication machinery from world renowned suppliers who are at 

the forefront of new and innovative technology. 

The range of quality machinery on show from Europe includes the 

fully electric press brake from SAFAN, the original inventor of electric 

bending with the new EC control, as well as the new RAS XL-Centre. 

Sheetmetal Machinery introduces this new folding innovation for 

roofing and architectural profiles, which is based on the XXL-Centre 

technology. By folding the part up and down the new model reduces 

material handling to a minimum, the company claims. 

Moreover, Sheetmetal Machinery exhibits the E-Ventures CENTU- 

RIO, an automatic sheetmetal slitting and cutting machine with automated 

coil warehousing systems. The laser cutting system uses the 

latest mid-size CO2 laser technology built by El.En. S.p.A. Combined 

with new fast linear motors 3-axis and CNC gantry system it is said to 

be capable of cutting acrylic with a polish quality on either extruded 

or cast types, metal and also wood. 

Other exhibits include an ergonomic electric press brake for small 

parts from Coastone, corner forming from ACF and the latest creation 

Ultimate Laser showcases hi-tech Laser 

and Waterjet cutting 

Being successful in a highly-competitive industry requires innovative 

minds and cutting-edge technology. Dandenong (Vic)-based Ultimate 

Laser possesses both and is primed for further growth, which is one 

of the reasons the company decided to exhibit at this year’s Austech. 

“Being part of Australia’s premier advanced precision manufacturing 

and machine tool exhibition provides us with the opportunity to exhibit 

our unique capabilities to an expected audience of more than 10,000 

visitors,” says Andrew Pleysier, Business Development Manager at 

Ultimate Laser. “Our aim at Ultimate Laser is to build mutually beneficial, 

long lasting relationships with new and existing clients. We have a 

large base of long-standing clients from a variety of industries, many 

of which have been with us from inception. We look forward to the possibility 

of showcasing our capabilities at Austech this year and expand 

our customer base.” 

Ultimate Laser was formed in 2004 with the commencement of 

their Dandenong laser cutting facility and has grown to become a leading 

one-stop laser and waterjet cutting jobbing shop in Victoria. The 

team offers custom cutting at competitive low pricing and just-in-time 

service with a combined experience in the laser and waterjet cutting 

industry of more than 30 years, and has recently added waterjet cutting 

capabilities to its business, using the latest technology for their 

advantage. 

“We realise the importance of top quality machinery and are deeply 

committed to investing in the latest equipment and technology, which 

in turn allows us to provide better and faster methods of manufacturing 

product resulting in various advantages for our customers,” Pleysier 

explains the company’s decision to operate the latest model machines 

from world-leading companies Bystronic and WJS, Waterjet Sweden. 

“By developing a reputation for quality product, providing prompt and 

impeccable service, extremely attractive pricing, standard lead times 

between 3 – 5 working days all strives to provide our customers with 

the best possible outcome.” 

Ultimate Laser runs five laser machines and one 5-axis Beveljet waterjet 

machine, operating a huge 6.5m X 3.1m bed size. The waterjet 

cuts most materials up to 150mm thick, including mild steel, stainless 

steel, aluminium, copper, brass, titanium, wood, plastic, rubber 

and much more. The material is cut with a cold cutting process without 

the effects of heat, which prevents hardening, warping, dripping slag 

or amalgamation. The waterjet machine is capable of bevel cutting and 

reacts flexibly to changing contours and materials. 

The state-of-the-art laser cutting capacity allows for the cutting of 

4m X 2m sheets made from mild steel (up to 25mm thick), stainless (up 

to 20mm), aluminium (up to 10mm), zinc, seal/annealed/alume, Bisalloy 

and many others. 

To complement the modern machines, Ultimate Laser uses advanced 

CAD/CAM software to generate drawings or develop customersupplied 

files for cutting. The Bysoft programming system simplifies 

preparatory work as well as nesting and enables simple, flexible part 

development. 

“Combining our programming facilities with our advanced laser 

and waterjet cutting machines allows our customers to benefit by full 

utilisation of all material with a minimum waste,” Pleysier says. “This 

means the final product has minimal material usage and cutting times 

are reduced.” 

Ultimate Laser Pty Ltd - Stand 630 

www.ultimatelaser.com.au 

from SIMASV Italy, a 30°>140° variable angle hydraulic notching 

machine AV226/PA-CNC. The punching head is controlled independently 

and operating via a changeover switch allows it to shift 

easily from the notching to the punching step. 

Sheetmetal Machinery Pty Ltd - Stands 662 and 682 

www.sheetmetalmachinery.com.au 


Unique insert cutting edge 

design coupled with 

high-precision body 

construction, provides 

superior cutting performance, 

a true 90°shoulder 

Milling Cutter. 

567 

NSW Toll Free 1300 307 099 www.seicarbide.com 

VIC 03 9548 8516 SA 0418 826 155 QLD 0418 732 729 


49

Preview 

Plasma cutting with laser precision 

Farley Laserlab will demonstrate a TruEdge II machine from their new 

and affordable TruEdge plasma cutting machine range. One of the special 

features of Farley’s TruEdge machines is Hypertherm’s True Hole 

cutting technology. The technology uses a specific combination of cutting 

parameters optimised for mild steel applications. The end result is 

claimed to show an up to 50% improvement in the shape of the hole. 

The patent-pending hole cutting technology vastly improves the capability 

of hi-definition plasma resulting in a quality that competes, at a 

fraction of the cost, with processes that were previously more accurate, 

such as drilling and laser. 

For anyone interested Farley Laserlab would like to invite visitors to 

bring in small dxf files that are less than 300mm to be cut as demonstration 

parts. 

In addition to this, Farley will also be exhibiting the NEW Zero Offset 

Bevel Head on a separate test rig. Farley will be showing the different 

type of cuts that are available on the new bevel. Cuts that can be performed 

on this new bevel are as follows: ‘K’ bevel, sharp bevel, sharp 

top blind bevel cut, cone bevel, bevel pipe hole cut, arc bevel cut and 

top bevel star without loop. 

H G Farley Laserlab Pty Ltd - Stand 591 

www.farleylaserlab.com.au 

Electric hydraulic portable hole punch 

At Austech 2011 Stainelec Hydraulic Equipment will demonstrate 

the new Kamekura Model RW-M2 electric hydraulic 

portable hole punch. According to Stainelec, the unique design 

of the RW-M2 hole punch allows the operator easy 

positioning by adjusting the movable back gauge as well 

as an LED lighting system which can clearly light up the 

desired punching position for accuracy to punch holes in 

the material piece. 

The inching button allows further accuracy to punch 

on pre-marked centre lines of the work piece material. 

RW-M2 produces 20 tons of punching force 

and has a double insulated 230 volt motor which 

drives the high powered two stage hydraulic 

system with auto return when the hole is punched. 

Weighing just 10.5kgs the unit is easily portable for site 

work and workshop operations. Designed for use with 

punching round holes from 8mm to 20mm in 10mm thickness 

materials such as copper and mild steel and 

6mm thick stainless steel for 8mm to 20mm diameter 

holes. Made in Japan, the RW-M2 produces a 

quick, clean and accurate hole. 

Along with new model RW-M2, an extensive 

range of Kamekura Seiki hand held hydraulic hole 

puncher units will be demonstrated at this year’s 

Universal cutting and sawing machine 

ProTUBE, a niche and specialised supplier of machinery, plant and 

equipment including consumables and wear items, will be exhibiting a 

KALTENBACH universal sawing and cutting machine KKS 450E. 

The trend towards automation has long made its presence felt in 

the steel construction and trading industries. As a manufacturer of 

sawing and drilling machines and also sheetmetal processing centres, 

KALTENBACH can offer optimum support with rationalisation and efficiency-raising. 

Because the automation process begins with material 

transport, the subsequent processing of the steel sections with saws, 

drilling machines and flame cutting through to the automatic sorting 

of good parts, off-cuts and remnants and distribution to subsequent 

production processes can be optimised and adapted to existing layouts. 

Ideally, the operator fills the magazines the evening before and 

the production steps are completed automatically overnight so that the 

material can be loaded and despatched the next morning. 

According to ProTUBE, steel trading sector customers who rely on 

KALTENBACH’s automation concept report up to 30% more capacity 

and a correspondingly shorter throughput time. 

ProTUBE Asia Pty Ltd - Stand 771 

www.protube.com.au 

Austech. Made in Japan, Kamekura hydraulic hole 

punchers are precision manufactured tools offering 

a life time of reliable service to any tradesman 

requiring to penetrate holes in sheet metal, 

stainless steel, copper, brass and aluminium. 

When punching the material, the operation is 

easy with no excessive pressure being forced 

from the user. 

These precision-made hydraulic hole 

punchers can be applied to any working position, 

the company claims, allowing the 

operator more flexibility to punch holes 

in confined situations for control panel 

work. Punching operation is simple, 

fast and easy requiring little effort. When 

punching the hole, a professional finish is achieved 

to the work piece with no damage to finished painted 

products. Extensively used in electrical switchboard 

manufacturing, plumbing/sink ware distributors 

and manufacturers, plant system operations and 

general sheet metal workshops. Stainelec Hydraulic 

Equipment is the sole Australian Agents and distributors 

of Kamekura Seiki hydraulic equipment. 

Stainelec Hydraulic Equipment Pty Ltd - Stand 667 

www.stainelec.com.au 


Preview 

Shop floor equipment and materials 

handling solutions 

At Austech Modern Tools will be displaying a range of new products 

for the first time, including SMARTVENT fume extractors and down 

draft welding tables offering a full range to suit most workshop needs 

including custom systems. Also on display will the the GOSAN CNC 

teach lathe model 2040 (500mm swing x 1000mm between centres) 

with a FAGOR 8055 controller. 

SKYHOOK lifting cranes are another highlight, ideally suited to machine 

parts lifting. A skyhook lifter can be attached to the machine, 

trolley or floor mounted, preventing workplace injuries. Other products 

on display will be a full range of FIRST precision milling machines & a 

FIRST MCV-1100 machining centre with Fanuc controller. HWACHEON 

high quality precision lathes (sold by Modern Tools since 1978), SHEN 

JANG automatic, semi-automatic and manual bandsaws, TECHPLUS 

precision drilling machines, S4 welding & positioning tables featuring 

a PLASMA NITRATED coated surface to prevent any weld spatter 

sticking to the table. 

Modern Tools Pty Ltd - Stand 579 

www.moderntools.com.au 

Taegutec launches Gold Rush series 

Taegutec launches its Gold Rush range of products at Austech 2011. 

Visitors are invited to come to the Taegutec stand to find out why it 

took over four years to research, develop and release this very complete 

product range. “The GR range will undoubtedly mark Taegutec’s 

desire and intention, not just in the Asia Pacific region but throughout 

the world during 2011 and beyond,” says Zeb Colic, Managing Director 

Taegutec Australia. 

The features of the Gold Rush Range include its distinctive premium 

appearance in a shiny gold colour, indicating added Golden Rush 

values like innovation in design, minimised built-up edges, extremely 

efficient metal removal , double sided technology, increased depth of 

cut capability , excellent surface finishes, prolonged tool and body life 

all adding up to lowered machining costs, he goes on to explain. 

Taegutec Australia Pty Ltd - Stand 600 

www.taegutec.com.au 

Automatic CNC beam line for drilling shaped 

and flat profiles 

At Austech Ron Mack Machinery will introduce the latest creation from FICEP, the “Excalibur 

12-1210DE”. According to Ron Mack, the automatic CNC beam line for drilling shaped and flat 

profiles is the first mono spindle gantry drilling line to process beams for those in the steel 

construction industry working with the “cantilever” system. The machine is suspended on and 

moves along its loading table, without interfering with drill chips or anything else lying on the 

floor. 

The gantry drilling line is claimed to 

feature low cost investment, reduced 

overall dimension, flexibility and high 

productivity due to its versatility. Thanks 

to a set of wheels mounted on bearings, 

the drilling unit main body slides on a 

sturdy support crossing the loading table. 

The support is equipped with a rack 

that, through a toothed pinion, guarantees 

precise movements. An electromechanical 

sensor surveys the origin 

of the workpiece and allows it to start 

the working cycle. The piece to be processed 

cannot move as it’s strongly clamped in the working position by an automatic doubleeffect 

hold-down (top and bottom clamping). 

Ron Mack will be running several presentations and information sessions throughout the 

exhibition. 

Ron Mack Machinery Pty Ltd 

Stand 660 

www.ronmack.com.au 


51

Preview 

GBS: New press brake generation 

FJP Manufacturing introduces the small and compact LAG MINI GP 

press brake, which maintains all main features of the bigger range of 

press brakes and is available in two models: MINI GP 515 and MINI GP 

815. Both models can optionally be equipped with a CNC and robots. 

According to the exhibitor, GBS press brakes represent a concentration 

of innovation which differs substantially from the traditional Press Brakes. 

“For years press brakes hadn’t been developed significantly; apart from 

the various options, the press brake has remained conceptually the same,” 

LAG’s Luciano Gasparini states, adding, “the GBS technology has considerable 

strong points that aim to become real benefits for the customer.” 

The GBS is claimed to be characterised by an extremely structural 

rigidity that eliminates the misalignment of the bending axis; this typical 

inconvenience of the traditional press brake is generally solved through 

application of deflection compensation systems. The design of the GBS 

eliminates this problem. Furthermore, the top beam is fixed to side 

frames, which slide on eight linear guides, eliminating friction. 

Thanks to the structural geometry the GBS is particularly suited to 

automation allowing applications for automation, robot and mechanical 

reference, high speed and precision. 

FJP Manufacturing Pty Ltd - Stand 715 

www.fjprecision.com.au 

Non-destructive testing and surface 

finish testing 

Carl Zeiss Metrology will be exhibiting the latest in CMM technology 

as well as non-destructive testing and surface finish testing. With O- 

INSPECT, Zeiss succeeded in bringing this multi-sensor system work 

of art to life. O-INSPECT means optical and contact measurements 

with one measuring machine, in one setting, on one workpiece, in one 

measuring run, Zeiss claims. The successful O-INSPECT multisensor 

measuring machine is available with a chromatic white light sensor 

which enables the measurement of parts that cannot be captured with 

a contact sensor or a camera. This includes very small and sensitive 

workpieces that feature a transparent, glossy or low-contrast surface. 

According to Zeiss, the measuring machine allows very easy, very accurate 

and thus very efficient inspection of complex parts. It can be 

used in the electronics and plastics industries, for medical and automotive 

technology, and precision engineering. 

With the latest Carl Zeiss Metrotom X-ray Scanner, it is now possible 

to measure highly precisely and non-destructively in areas where 

only destructive inspection was possible before or no quality assurance 

took place at all. Metrotomography allows to measure the interior of a 

workpiece: all recorded data can be applied to all areas of quality assurance 

and be evaluated. Non-destructive testing technology, such as assembly 

inspection, damage and porosity analysis, material inspection 

and defect checks is possible as well as traditional evaluation, reverse 

engineering applications or a comparison of geometries. 

Carl Zeiss Pty Ltd - Stand 663 

www.zeiss.com.au 

Laser cutting quotation system 

Following on from its successful UK launch, ipLaser is showcasing 

its laser cutting quotation system at Austech 2011. 

Unlike traditional quoting tools, the company claims, ipLaser 

uses a CAD drawing as the source of information for the quote. You 

no longer need to rely on estimates of a part shape or time. All of 

this work is done for you. According to ipLaser, ipLaser addresses 

many of the problems faced by “traditional” quoting methods. The 

resultant quotes are based on a strict set of rules and parameters 

which ensures a consistent quote. The quoting process has been automated 

to the point where significant savings in the time to produce 

a quote can be made. The user is required to provide a CAD drawing 

of the part, the minimum information to define a part, and the system 

takes care of the rest. The technology used by the ipLaser quoting 

engine not only ensures that the quotes are consistent, but they are 

also accurate. 

The algorithm that calculates the part processing time is modelled 

on a physical machine, rather than using linear distance. The 

system takes into account deceleration/acceleration required when 

cornering. This means that your quote for a complicated part (for 

example, a saw blade) is not the same as for a simple rectangle of 

the same distance. Material pricing is also accurate and competitive, 

with ipLaser calculating material prices based on an approximate 

true shape nest. 

The ipLaser system is claimed to provide a consistent and rapid 

method for providing quotations to customers of laser cutting providers. 

It can be used as an in-house tool by the laser cutting provider, 

or as a portal for self-service quoting by the laser cutting customer. 

“Using the ipLaser quoting solution in-house can lead to substantial 

reductions to quote response times,” Technical Director Peter Olle 

says. “However, providing a portal to your customers where they 

can obtain a quote instantly is the ultimate solution. ipLaser comes 

equipped with the technology to provide you with a 24/7 store front. 

Giving customers the ability to quote and order via your ipLaser portal 

not only gives the customer the freedom to obtain a quote when 

they need it, but minimises your cost to provide the quote.” 

Iplaser Pty Ltd - Stand 668 

www.iplaser.com 


Preview 

High quality workholding and machine tool accessories 

Romheld Automation will exhibit a range of high quality workholding and machine tool accessories and 

automation tooling with special emphasis on flexibility, reliability and repeatability. 

Want to automate but short of cash Romheld suggests the use of the new Schunk spindle grippers 

and to use your machine as a robot for auto load and unload of parts to be machined. 

Another suggestion is to view the BTop3 chuck from Hainbuch. This is a not so traditional 

three jaw power chuck with quick change jaws. In less than two minutes Romheld reports 

that it can be converted from a jaw chuck to an extremely rigid expanding mandrel simply by 

removing the chuck jaws and a cover, inserting a mandrel body and tightening three socket 

screws. Add an endstop and an expanding sleeve and you’re ready to machine the second op. 

Need a powerful collet chuck Simply remove the mandrel and insert a collet chuck body. 

You can also quick change between collet, mandrel and top jaws for stationary clamping on 

milling machines, with the base unit either manually or hydraulically actuated. None of these 

changes requires any clocking up or removal of the chuck from the machine spindle. The 

only tools required are allen keys. 

The Schunk Vero-S system provides very accurate repeatable positioning with clamping 

forces to 40kN to allow quick change of fixtures, base plates, vices etc. To change 

a fixture simply turn on the air and the receivers are released. Exchange fixtures, turn 

the air off and the new fixture is located within microns and clamped strong enough for 

heavy machining. 

Auxiliary air blasts ensure the receivers remain clear of coolant and chips allowing 

untended auto changes. 

Air actuated permanent magnet grab heads from Goudsmit allow remote control of powerful 

rare earth magnets for automated handling of ferrous product in difficult environments 

including high temperature and flammable. 

Visitors are encouraged to try out the Stoeger self-feeding screwdriver for fast and simple 

screw insertion and tightening. 

Romheld - Stand 688 

www.romheld.com.au 

110535 QMTHalfpage2011:Layout 1 15/4/11 11:19 AM Page 1 

Automatic Horizontal & Vertical Tool Changer 

Automatic Head Magazine 

• Huron 5 Axis Machining Centres • CNC Lathes & Mills • Vertical Machining Centres • CNC Wirecut EDM • Digital Readouts 

QUALITY MACHINE TOOLS PTY LTD 

Engineering Machines & Accessories 

Tel: +61 3 9587 8788 Fax: +61 3 9587 5788 

91-93 Malcolm Rd, Braeside Vic 3195 

www.qualitymachinetools.com.au sales@qualitymachinetools.com.au 

KEY FEATURES: 

• X Axis – from 1500 mm to 10200 mm travel 

• Y Axis up to 5000 mm travel 

• Z Axis up to 1800 mm travel 

• Optimal Centre Layout of Spindle System 

• Unique Damping & supporting design for 

X & Y Ball screws (Bigger machines) 

• Fully automatic 5 Face Machining 

• Built in High Speed Kessler HSK Spindle 

• Automatic Tool Length & Work Piece 

Measurement 

• Fanuc 18 i / Seimens 840D / Heidenhain iTNC530 

CNC Controllers Offered 

• Heidenhain Scale Feedback 

• 90 Tool Automatic Tool magazine 

2 Axis Head 

Extended Head 

784 


53

Preview 

Rolling machines: exceeding 

expectations 

Factory Equipment Sales/DAVI will feature their DAVI Rolling Systems 

at Austech. In Australia there are companies which have purchased 

multiple DAVI plate rolling machines - for example RPG Group have 

acquired eight DAVI plate rolls used for general purpose, pipe and wind 

tower manufacture, while Hilton Manufacturers has three high production 

models. This company manufactures 20,000 fuel tanks for trucks 

for the local and international markets. Tyco has two high production 

DAVI models specifically designed for rolling pipe collars up to 200 

units per day. 

Two DAVI MCP 3232 heavy duty section rolling machines have been 

sold into QLD and Victoria that are able to roll 410UB and 250mm angle. 

Recently a DAVI MCB 3075/S (3000x75mm) super heavy duty plate 

rolling machine was commissioned for DT Hi Load in Perth to roll bodies 

for heavy duty haul trucks for the mining Industry. 

Able Industries Engineering Pty Ltd secured a contract that required 

rolling 17,000 vessels in short time. A DAVI MCA 2019 CNC machine was 

purchased and productivity has reportedly exceeded all expectations. 

FES specialises in all types of machines offering options from 

economy models upwards but mainly focusing on value for money and 

exceptional service. FES states that control, efficiency and productivity 

are priorities in all DAVI Rolling Systems. 

Fabrication Equipment Sales - Stand 684 

www.fes.net.au 

DAVI - www.davi.com 

Laser cutting and metal fabrication 

New Touch Laser exhibits its laser cutting and metal fabrication capabilities 

at the Manufacturers’ Showcase Pavilion. New Touch prides 

itself on its ability to provide a cost effective, high precision means of 

processing a wide range of materials; offering design flexibility, perfect 

cut qualities, high tolerances with quick turnarounds. 

Joined by New Touch Fabrications, New Touch Laser is backed by 

three locations, seven lasers, press brake and Mig and Tig welding. 

The company’s machines have the ability to process a wide range of 

materials to meet all sheetmetal requirements from 2D, 3D & rotary 

laser cutting, laser marking, folding and welding to your specifications 

ensuring perfect high-quality finishes, always. To ensure faster lead 

times, New Touch carries most materials in stock, including mild steels, 

stainless steels, aluminium, galvanised steel, zinc seal/allume, acrylic, 

MDF and plywood. 

“Austech provides an opportunity for us to demonstration the ability 

and expertise of our highly skilled staff,” company director Brad Drury 

says. “We can assist you on the best solution to produce your product 

as efficiently as possible. From prototypes through to productions we 

can adjust and modify parts to ensure ideal product results.” 

New Touch Laser Cutting Pty Ltd - Stand 774 

www.newtouchlaser.com.au 

High-quality finish for automotive, aeronautical, marine or electronic products 

Décor Engineering will showcase its main areas of expertise at 

Austech. 

These are: industrial stencils or “masks” (hand-made to exacting 

standards by precision engineers); vacuum metalising of a variety of 

components; and specialised coating and painting, including the use 

of reflective, conductive and protective coatings. 

The company’s stencils are created for complicated components 

that require either painting, metalising, gluing or shield coating and 

are made from materials that can withstand constant, high-volume 

use in both manual production or robotically controlled production 

lines. Décor Engineering creates three-dimensional stencils for a 

wide variety of products. Jigs and stands are also provided. 

The company’s vacuum metallising (PVD) technology is an environmentally 

friendlier process than traditional chroming and has 

many applications. Metal finishes can be highly reflective or controlled 

to allow only a predetermined amount of light or heat reflection. 

This PVD technology can also be used to provide shield coatings 

for electronic and radiation-sensitive casings. These applications are 

highly sought after in the aviation industry where weight and durability 

considerations are paramount. 

Metal finishes can be used on all non-porous surfaces such as 

plastic, glass and aluminium. This technology was used to provide the 

pure gold coating on the Melbourne Commonwealth Games batons. 

Décor Engineering (Aust) Pty Ltd - Stand 647 

www.decorengineering.com.au 


Come and speak with us at Austech to learn more about the comprehensive 

range of products, and after-sales service offered by Haco Australia. 

Kingsland Steelworkers 

CNC Plasmas 

CNC Pressbrakes 

Bomar 

Bandsaws 

And what is a quality machine without professional sales and support backup 

Haco Australia has highly skilled, factory trained, service technicians to ensure your machinery operates 

to manufacturers specifications. We go to any length to ensure that your needs and expectations are 

met on time, every time. 

For all enquiries Kurt Bossuyt on (03) 9791 8255 

Australia wide call: Geoff Archer on (08) 9414 8009 

email: sales@hacoaustralia.com.au 


55 

web: www.hacoaustralia.com.au

Preview 

Extensive range of high-speed steel, 

saws, clamps, grinders and more 

The many products available through Industrial Tool and Machinery 

Sales may be viewed at Austech. This company is the importer, national 

wholesaler and sole Australian distributor for Slugger® and Holemaker® 

Magnetic Base Drills, Slugger® and Holemaker® Annular Cutters 

and accessories, Drill Doctor® Sharpening Machines, Ehoma® Industrial 

Welding Clamps, NPK® Air Tools, MACC Cold Saws and Bandsaws, 

Darex® High-end Sharpening Machines and Worksharp® Tool 

Sharpening Machines. 

ITMS also imports and distributes a wide range of Trademaster® 

bandsaws, cold saws, metal cut-off saws, belt grinders, bench grinders, 

fans, ventilators, Star® spray guns, and all the allied parts and accessories. 

With 18 different models of Slugger® or Holemaker® Magnetic 

Base Drills stocked, the company claims to have the largest range 

of magnetic base drills in Australia. A similar claim is made for their 

annular cutters. The company stocks more than 750 different types 

of high speed steel, tinite coated, cobalt tinite coated, titanium carbon 

nitride coated and tungsten carbide tipped annular cutters. 

ITMS has recently taken over MACC Machinery. Consequently an 

extensive range of cold saws and bandsaws are now in stock: From 

portable to fully automatic bandsaws and 225mm diameter to 350mm 

diameter coldsaws. 

Distribution is Australia-wide with representatives in each state and 

warehouse facilities in Queensland, Victoria, Western Australia, Tasmania 

and South Australia. 

The company has more than 20 years experience, and prides itself 

on a reputation for a large range of quality tools, and expert staff. 

Industrial Tool and Machinery Sales - Stand 598 

www.industrialtool.com.au 

New multi-wavelength laser platform 

Universal Laser Systems, Inc. (ULS), a leading manufacturer of CO2 

lasers and systems, together with Laser & Sign Technology (LST), a 

leading laser machine distributor across Australia, will introduce a new 

multi-wavelength laser platform at Austech. The PLS6MW features a 

fibre laser for direct metal marking that can be interchanged with a CO2 

laser for processing materials like wood and plastic – all in the same 

laser system. 

The PLS6MW model builds on Universal’s patented Rapid Reconfiguration 

technology, giving customers the ability to interchange 

laser sources without the need for realignment or special tools. The 

PLS6MW has a 813x457mm (32x18-inch) processing area and supports 

a 30-watt fibre laser source that can be interchanged with Universal’s 

CO2 lasers ranging from 10 to 75 watts. 

The fibre laser source is ideal for cutting foil and marking a broad 

range of metals like stainless steel, titanium, copper, brass, aluminium 

and carbide plus some plastics including Delrin and ABS. The CO2 laser 

source is ideal for engraving and cutting operations – specifically 

wood, acrylic, glass, anodized aluminium, fabric and other organic 

materials. In addition to the 10.6 micron wavelength, Universal’s CO2 

lasers are available with a wavelength of 9.3 microns, a great attribute 

for PET marking and other applications. 

To interchange laser sources from a fibre laser to a CO2 laser and 

back again with no tools it claimed to give the user incredible production 

flexibility and is unique to Universal. 

LST - Stand 625 

www.lastech.com.au 

Diverse range of CNC profile cutting/robotics expertise 

NC Technologies will be exhibiting their diverse range of CNC profile 

cutting/robotics expertise at Austech and are happy to discuss how 

they can tailor a solution for profile cutting customers. Their experience 

includes preventative maintenance, breakdown repair, control 

system retrofits, machine installation, commissioning and training, 

wireless communication upgrades and general automation and programming. 

Cross-discipline expertise is available across multiple 

platforms, including the NEW Hypertherm EdgePro controller enabling 

claimed “revolutionary” True Hole cutting technology. 

As an approved Hypertherm agent, NC Technologies sells, services 

and installs a wide range of Hypertherm mechanised plasma 

systems. Their retrofitting portfolio includes plasma, oxy, waterjet 

and bending machines with controls from Kinetic Engineering, 

Burny(CMC) and Hypertherm Automation. These controls offer a 

claimed exceptional performance, ease of use and value for money. 

NC Technologies offers an efficient breakdown service resulting in 

a minimum of downtime and a preventative maintenance program. 

The company is the agent for MTC Nesting software including 

ProNest, TurboNest and NestMaster. Accordingly, NC Technologies 

will meet all software needs: Whether simply upgrading to the latest 

version or never having used CAM software before. Additionally, 

the company can provide custom processor information for machine 

interfacing, no matter how old or unique. 

NC Technologies - Stand 527 

www.nctech.com.au 


55-61 Nissan Drive, Dandenong, Victoria 3175 

Tel: (03) 9706 8066 Fax: (03) 9706 8067 

sales@appliedmachinery.com.au 

www.appliedmachinery.com.au 

Australian Manufacturing Technology May 2011 57

Preview 

True multi-paradigm design platform 

At Austech, LEAP Australia will be showcasing the latest versions of 

the PTC Creo Technology for Computer Aided Design and ANSYS for 

Simulation and Analysis. 

Pro/ENGINEER is now called Creo Elements/Pro. The four key 

themes of Creo include: 

• AnyRole Apps: Customers get the right tool, for the right user, at the 

right time, with task specific user interfaces, making Creo a claimed 

easy to use application. 

• AnyMode Modeling: Creo will provide the industry’s reportedly only 

true multi-paradigm design platform, enabling users to design in 2D, 

3D direct, or 3D parametric. Data created in any mode will be fully 

accessible and reusable in any other mode. 

• AnyData Adoption: Users can incorporate and edit data from any 

CAD system, and share it back out again. 

• AnyBOM Assembly: Product development teams creating highly 

configurable products can use BOM-driven assemblies and PTC’s 

Windchill PLM software to “design” hundreds of unique configurations. 

ANSYS 13.1 

The advanced technology behind the new ANSYS 13.1 release includes 

hundreds of new features that the company claims make it easier, faster 

and cheaper for users to bring new products to market. 

The three key improvements evident in ANSYS 13.1 are: 

Greater fidelity via new solver methods. As engineering requirements 

and design complexity increase, simulation software must produce 

more accurate results that reflect changing operating conditions. 

Stillam AU and SNC Solutions 

Stillam AU, the Australian supplier of Edgecam CAD/CAM Software, 

partnering with SNC Solutions supplier of Radan Sheetmetal 

CAD/CAM Software will be located at Stand 692 at this year’s 

Austech Show. According to the company, the goal is to offer a 

complete CAD/CAM solution for both metalworking and sheetmetal 

manufacture. 

Stillam AU will be showcasing the new version of Edgecam 

2011 Release 2, boasting an array of new features and software 

enhancements. SNC Solutions will be showcasing Radan, a complete 

sheetmetal solution. 

Strong competition locally and globally, the possibility of new 

regulations in the manufacturing arena and the trend towards new 

clean technologies are contributing factors in forcing Australian 

businesses to look for more economical, efficient and cleaner 

manufacturing methods. That’s where Stillam comes in. Stillam 

offers its customers an easy solution for this transition to efficient 

green, lean manufacturing and production flow. 

Edgecam is designed to cope with programming the simplest to 

the most complex components and offers full support for the latest 

CAD, machine tool and tooling technology. 

Radan is the total CAD, CAM solution for the sheetmetal industry. 

Radan’s software is claimed to significantly reduce inventory 

and increases material utilisation, allowing you to realise true return 

on your investment. 

Stillam AU - Stand 692 

www.stillam.com.au 

ANSYS 13.1 features an electromagnetic transient solver that produces 

higher-fidelity results in dynamic simulation environments, among 

other new features. 

Higher productivity built on an adaptive architecture. ANSYS 13.1 

includes dozens of features that are claimed to minimise the time and 

effort product development teams invest in simulation. 

Performance innovation via software and computational power. AN- 

SYS 13.1 can provide speedup ratios that are dramatically greater than 

previous software releases. Complex multiphysics simulations can be 

accomplished more quickly and efficiently, speeding up product development 

and market launch initiatives, it is claimed. 

LEAP - Stand 599 

www.leapaust.com.au 

IP67 798 series 

coolant proof 

electronic caliper 

LS Starrett introduces the new IP67 798 series 

coolant proof electronic caliper. This new 

electronic caliper provides an ip67 protection 

against coolant, water, chips, dirt, dust and other 

contaminants in hostile work environments. 

The 798 includes an RS232 output port for data 

transmission into your PC or Starrett Data Collection 

systems. 

These full-featured electronic calipers are 

built with customary Starrett quality and workmanship. 

Available in 0 – 6 inch ( 150 mm ) 0 

– 8 inch ( 200 mm ) and 0 – 12 inch ( 300mm ) 

Large, easy to read LCD .310 character height 

digital readout with a resolution of 0.010mm. 

Features include induction type linear encoder 

system, heavy duty bar and slide, 3.5 mm thick, 

hardened stainless steel measuring surfaces for 

long life, fine adjustment, slide lock, linear accuracy 

meets din 862, inch/ mm conversion, zero 

at any position, automatic shutoff of the display 

after 30 minutes non-use, reactivation of display 

with movement of slide with no loss of position. 

The LS Starrett stand will also feature a comprehensive 

selection of bandsaw blades and 

tools for electrical, plumbing and general construction 

industries. 

LS Starrett Company of Australia Pty Ltd 

Stand 544 

www.starrett.com.au 


Glimpse the tip of the iceberg 

600 Machine Tools’ display at Austech, will include Colchester-Harrison 

lathes, along with Electrox laser-markers, digital readouts, and accessories. 

The turning machines will be demonstrated by Ross Whittle of 

Advanced Machine Tools, the company’s exclusive agent for machine 

tools in Victoria. 

Already the biggest manufacturer of turning machines in Europe, the 

UK-based 600 Group recently acquired a large centre of excellence in 

Poland that will produce high-spec versions of its world-famous Colchester-Harrison 

lathes – which boast a pedigree that began in the 19th 

century. According to the exhibitor, 600 Machine Tools has a sound 

reputation with company owners and workshop managers throughout 

Australian industry for the quality of its machines, and its exemplary 

service and training programs. 

Sydney-based 600 Machine Tools is now the sole outlet in Australia 

for another member of the 600 Group, Electrox of Letchworth Garden 

City – a company that has harnessed laser technology to become an expert 

in its field. The Hertfordshire-based firm is an acknowledged global 

leader in the design, development, and manufacture of laser marking 

systems. 

These machines will be demonstrated at Austech, by the agent for 

Victoria, Melbourne-based Ruby Works Ltd. Managing director Robert 

Reid says: “Many industries that have not traditionally used laser marking 

are embracing the benefits of permanently marking components 

and finished products, and more sectors are now switching to laser 

marking from such traditional techniques as stamping, pin, and dotpeen 

marking.” 

He adds: “Now available is the Electrox Raptor laser – the first laser 

marking system to be powered by EF technology. Such is its faith in this 

new system that Electrox is able to give EF Technology a four year warranty 

– FMTool_April2011:Layout the longest warranty available anywhere 4 16/3/11 in the laser 4:16 marking PM industry.” Page 1 

Preview 

The machines and ancillary equipment on display at this year’s 

Austech represents the tip of the iceberg, because 600 Machine Tools 

is the exclusive distributor in the Asia-Pacific region for all 600 Group 

products, including the workholding systems of Parat, Crawford, and 

Pratt Burnerd. 

Additionally, the Sydney-based company represents such global 

‘blue chip’ brands as Fanuc Robodrills, YCM machining centres, Joemars 

EDMs, Paragon cylindrical grinders, Erlo drills, and TOS Varnsdorf 

horizontal milling and boring machines, along with a range of mills, 

saws, and other competitively-priced machine tools. 

600 Machine Tools recently moved its regional head office into 

larger premises at Foundry Road in Sydney’s Seven Hills, close to the 

M2 motorway, and has branches and distributors in Australia’s cities. 

600 Machine Tools Pty Ltd - Stand 666 

www.600machinery.com.au 

650 


59

Preview 

B&C Plastics continues its innovation 

journey with 3D printing technology 

In its ongoing desire to grow and improve, B&C Plastics decided to take 

part in this year’s Manufacturers’ Showcase and is constantly looking 

for new opportunities and ways to innovate by scanning the environment 

for new ideas in Europe, North America and Asia as well as closer 

to home. 

B&C Plastics specialises in plastic injection moulding and toolmaking 

for a variety of industries including homeware, mining, building & 

construction and electronics, turning design ideas in to prototypes 

and market-ready products through a sophisticated range of machinery 

and processes. 

B&C Plastics recently identified a piece of UK-based technology 

which will complement and expand upon B&C Plastics existing activities. 

The technology involves a new three dimensional printing process 

which the B&C Plastics team has now brought to Australia with exclusive 

rights to use it here and in New Zealand. The technology involves 

surface decorative technology and a sublimation printing process. 

The B&C Plastics team have created a sister company, iPersonalised, 

to focus specifically on the new technology, working with a range clients 

to create customised products for single and mass production. This Technology 

will be on display for the first time in this country in May. 

Royston Kent, of B&C Plastics and iPersonalised is delighted with 

the feedback so far: “We’ve shown the new 3D printing process to a 

number of existing customers, as well as potential customers at trade 

shows and the response has been phenomenal. From mobile phone 

covers to fishing reels, the way this technology can be used is endless 

and our customers are suggesting even more ways this unique process 

can be used! We can print on a range of surfaces including steel, plastic, 

glass and ceramic and we already have our first orders”. 

To make purchasing one-off items as easy as possible for the consumer, 

the IPersonalised website will allow certain items to be selected 

and paid for completely online, such as mobile phone covers: 

“We aim to provide a straightforward way for customers to select 

an image they would like to use, and to select the medium they would 

like it printed on and to complete the transaction online quickly and efficiently” 

says Royston. 

A collaborative approach to doing business is instrumental to the 

B&C Plastics and the iPersonalised team. A collaboration being developed 

at iPersonalised is working with local designers and encouraging 

them to submit designs to iPersonalised to be used by prospective 

customers. 

Royston sees the new venture as an ideal way to increase the value 

provided to clients “Our sister company will have something to offer 

our existing B&C Plastics clients, while new clients who come to us via 

iPersonalised may also have the need for B&C Plastics products and 

services”. 

It also offers the opportunity for additional revenues streams 

through the development of a new business model around the exclusive 

distribution licence for the technology in Australia and New Zealand. 

Officially launched on 16th May 2011, the new company and its 

technology demonstrate the desire by the team to continually improve 

and evolve the value proposition offered to customers. 

Since its purchase by the two directors in 2006, the company’s 

focus has been on building strong relationships with customers, providing 

a rapid response to new requirements and offering innovative 

solutions. This focus has enabled B&C Plastics to triple its customer 

base and turnover by concentrating on its key unique selling points of 

superior customer service and product quality. 

Always looking to improve and a clear advocate for innovation, the 

company has engaged with a number of innovation programs in the 

past to remain at the cutting edge of what it does. These programs 

include Innovation Coaching, a joint initiative of the Australian Institute 

for Commercialisation (AIC) and Queensland Government’s Department 

of Employment, Economic Development and Innovation (DEEDI). 

Since completing an innovation program with the AIC, B&C Plastics 

has continued to grow, acquire new machinery and improve quality 

standards, having recently begun the application process for ISO9001 

and ISO14001 accreditation. 

B&C Plastics Pty Ltd - Stand MS9 

www.bcplastics.com.au 

New release in integrated CAM software package 

At Austech 2011, SolidCAM will be 

showcasing their latest product release, 

InventorCAM Xpress, which has been 

added to their already popular Inventor- 

CAM family of integrated CAM software 

products for Autodesk Inventor and AutoCAD. 

InventorCAM Xpress is being offered 

at a surprisingly affordable price 

(AUD$2500 +GST). This offers a 

unique chance for all Autodesk users to 

experience the power, time savings and 

accelerated learning curve of integrated 

CAM. InventorCAM Xpress includes the most popular 2.5D milling 

operations and 3D surface machining functionality, truly setting the 

standard for “power to price”. 

The advantages of InventorCAM Xpress do not end simply with 

price, as it is based entirely on the full InventorCAM solution and so 

provides a number of key benefits: 

• Upgrade paths available to cover all aspects of CNC machining, 

such as Advanced Geometry Programming, Multi-axis milling, 

Lathe, Wire EDM or Mill-turn machine programming. 

• Upgrade paths take into account existing functionality, so the initial 

investment in Xpress is not lost! 

• The Xpress interface is 

common throughout InventorCAM, 

so adding additional 

machines or modules 

is just an extension of what 

is already known. 

• InventorCAM’s singlewindow 

integration with 

Autodesk Inventor provides 

full associativity between 

the CAM toolpath and the 

Inventor native design model 

• The user has access to Inventor’s assembly and part functionality 

throughout the CNC programming phase, which can be used to 

manipulate the toolpath through additional geometry or sketches, 

as well as providing the ability to add in fixtures, clamps or casting 

models. 

InventorCAM Xpress is supplied with an extensive library of free tutorial 

videos and training documentation, along with the backup of a 

technical support team. 

SolidCAM ANZ - Stand 610 

www.inventorcam.com.au 


Preview 

ESPRIT CAM reduces cycle time from days to minutes 

ESPRIT by DP Technology (AB CADCAM) 

will again be exhibiting at Austech 2011. 

In manufacturing these days, the complementary 

combination of CAD software, 

multi-tasking machine tools and the fullspectrum 

CAM needed to drive them is 

not unlike the age-old “chicken or the 

egg” argument: Which came first 

Regardless of your answer, the need 

for a complete solution capable of producing 

the ever-more complex parts demanded 

of manufacturers is apparent. 

For CNC Programmer Brandon Marcotte, 

a 5-year employee at Task Force 

Tips, switching to ESPRIT has taken the 

guesswork out of his job. “ESPRIT programming 

is straightforward enough that 

it’s easy to see what changes need to be 

made,” Marcotte says.“It’s visual. You’re looking at solids rather than 

numbers and it’s all the same no matter who’s programming it.” 

Standardisation and the simple assessment of necessary changes 

are two parts of the equation that, at its heart, is geared at generating 

accurate toolpath and taking the complexity out of complex machining. 

“We took two steps back to take 10 steps forward,” Marcotte says. 

“With ESPRIT, it’s a huge leap forward because the technology to produce 

the G-code is supportive of the full capability of our machine 

tools.” 

In the end, it’s all about saving time. 

For instance, to make the main body of a 

portable monitor (a device used when water 

pressure is too strong to hold a hose by 

hand) in the past, the part had to be loaded 

onto a machine tool four separate times, 

which meant “scheduling the workload on 

the floor for a month before the part went out 

the door,” Price says. 

By implementing ESPRIT, Task Force Tips 

was able to cut down on machining time by 

streamlining processes and gained a 63 % 

reduction in the time required to machine the 

part. 

“Now we load it into a machine one time 

and it’s completed,” Price says. “Before, the 

handling time on the part was an hour. It’s 

now 22 minutes. It was one of those things 

where you can just do a couple of clicks in 

ESPRIT and have the whole thing programmed.” 

The value of the symbiotic relationship between software and machine 

tool can’t be underestimated. “If parts had remained simple, we 

would have had no idea what we were missing out on,” Price says. 

“Our biggest accomplishment as a company regarding ESPRIT is that, 

because of the software, we can fully utilise the capabilities of our machine 

tools.” 

ESPRIT by DP Technology (AB CADCAM) - Stand 645 

www.dptechnology.com 

The standard in intelligent CAD/CAM solutions 

ons 

• Production Machining 

• Multi Axis Machining 

• Mill / Turn Machining 

• Reduced Programming 

• Reduced Machining Times 

• Cad to Cam Interoperability 

• Mould and Die 

• Intelligent Features 

The world’s most powerful sheet metal 

• Solids Based Machining 

CAD/CAM software 

• Automatic Feature Machining 

• 

2D & 3D Solid Design 

• Punching 

• Profiling 

• Nesting 

• Bending 

• Cost Estimation 

• Process Management 

www.stillam.com 

Tel: (03) 9584 9733 • info@stillam.com.au 

Working in conjunction with SNC Solutions 


61

Preview 

Performance Unequalled... R35/38 

HARMONY ENDMILL 

Sutton will present the Harmony range of endmills at Austech. Harmony 

represents a claimed latest technology to provide increases in both performance 

and tool life. The key to successful milling is to minimise or 

eliminate the vibration produced in the cutting action. This is known as 

a build-up of harmonics in the work piece, which can be detrimental 

to the tool life of the endmill. Often this vibration has been rectified by 

slowing down the cutting speed and feeds, altering the size of the cut 

and increasing the rigidity of the set-up. The Harmony Endmill overcomes 

vibration, through a combination of tool design, micro geometry, 

material & coating, without the need to sacrifice productivity. 

A combination of a unique unequal flute helix & various optimisations 

with regard to the end-teeth geometry, provides a stable/chatter 

free cutting action. 

35-38° unequal flute helix, reduces the harmonic build up 

in the workpiece, resulting in smooth chatter-free milling 

in various types of milling techniques, increasing your productivity. 

45° Corner chamfering provides added strength to the endmills 

particularly in semi-roughing & roughing type milling 

applications. 

The gash grind of the endteeth blends to the outer corner 

of the 45° chamfer, strengthening the design in this area. 

Post grind treatment of cutting edges, engineered specifically 

for the relevant material application. 

The Harmony range is available in both PM-HSS and Carbide. VHM- 

ULTRA Harmony Endmills are made from VHM-ULTRA, an ultra fine 

grain type (0.5μm) which offers the best wear resistance in high performance 

milling applications. 

The carbide Harmony range is paired with AICrN coating, which exhibits 

an unmatched degree of oxidation resistance and hot hardness. 

These properties have triggered a quantum leap in tool wear resistance, 

allowing for significantly higher cutting speeds. 

Sutton Tools Pty Ltd -Stand 555 

www.sutton.com.au 

Investing in Queensland 

Queensland and the Economic Development branches of the Gold 

Coast City Council (BusinessGC) and Logan City Council (Logan Office 

of Economic Development) are co-exhibiting at Austech . 

Queensland continues to set the pace for economic growth in Australia. 

The manufacturing industry plays a major role in the growth of 

the state particularly in the coal and gas industries, building and infrastructure 

industry supply chains. 

If your business is looking to establish a footprint in Southeast 

Queensland, Trade and Investment Queensland, BusinessGC and Logan 

Office of Economic Development can assist your business with 

various services including: providing comparative information such 

as business costs and skills availability; private tailor-made business 

cases for prospective investors; assisting with site selection; accessing 

government funding and programs; liaison with businesses to 

streamline the development process in councils; facilitation introductions/meetings 

with relevant companies and service providers in the 

region and state; provision of ongoing assistance and opportunities 

after establishing operations in the region. 

Companies which have made recent investments in the SE Qld 

region include: Stramit, VISY, ALSPEC, Eco-Kinetics, Shred-X and 

Bendigo Relocatable Buildings 

Latest in 3D scanning solutions 

Showcasing 3D scanning technologies at 

Austech together, is Wysiwyg 3D and Qubic, 

combining knowledge and experience to provide 

both sales and service to suit a wide 

spectrum of industries. 

Wysiwyg 3D is Australia’s only leading 

independent service provider and authorised 

dealer for Geomagic - 3D software for 

creating digital models of physical objects. 

Specialising in 3D measurement, reverse engineering, 

inspection and analysis Wysiwyg 

3D offers mobile scanning technology, parts 

can be sent to the company’s premises up to 

2 ton in weight or may be scanned at the customer’s factory. With five 

scanners in their range, Wysiwyg 3D engineers can decide on which 

scanner best suits the customer’s application whether it’s an engine, 

car or a mining bucket. Wysiwyg 3D can supply data in a variety of file 

formats to suit CAD/CAM packages including IGES, STEP STL or OBJ. 

Qubic has a comprehensive range of 3D and 4D scanning solutions. 

Their 3D scanners can scan items from the size of a tooth to buildings, 

with accuracies up to 0.007mm. 4D technology can scan moving 

objects. Their industry-leading knowledge and understanding of 

3D scanning technologies is continually demonstrated to customers 

in competitive benchmarking tests. Industry leading brands such as 

Konica Minolta have partnered with Qubic for the long term, providing 

ongoing stability and support to customers including those in defence 

and medical. 

This year’s show will feature the: 

Surphaser – a terrestrial scanner used for large scale projects including 

cars, boats, factory layouts and mining equipment with a sub-millimetre 

accuracy. 

Geomagic - Lawrence Rajah Account Manager to answer all questions 

about the latest in reverse engineering and Inspection software. 

The Artec 4D/3D scanner - Can scan objects that are moving in 3D 

and extract 3D frames of an instant in time. Capable of scanning people 

with real facial expression and body shapes for animation or medical 

imaging and lastly the Konica Minolta group of scanners. 

Wysiwyg - Stand 773 

www.wysiwyg3d.com.au 

Trade & Investment Qld- Stand 674 

www.investqueensland.com.au 

www.businessgc.com.au 

www.loganbiz.com.au 


Productivity Package 

DOOSAN MILL TURN LATHE + HARTFORD VERTICAL MACHINING CENTRE 

See you there 

24th - 27th May 2011 

Melbourne Convention 

& Exhibition Centre 

See us 

at stand 

602 

Only at 

Austech 

DUAL Machine Productivity Package 

ONLY $199,995 * 

Own both of 

these machines 

from as little as 

$787 per week # 

Doosan Lynx 300M 

• 410mm turning diameter 

• 712mm turning length 

• 255mm chuck 

• Full contouring C-Axis 

• 4 x rotary tools 

• Auto tool setter 

• High pressure coolant 

• Link type chip conveyor 

• The latest Fanuc 0iT-D controller 

• Manual guide i conversational programming 

Hartford LG 1000 

• Travel X-1000, Y-510, Z-630mm 

• 11kW main spindle power 

• 8,000rpm spindle speed 

• Fast action arm type tool changer, 24 tools 

• 20 bar (290 psi) through spindle coolant 

with filtration system 

• Coolant nozzles around the spindle 

• Chip conveyor with coolant flushing system 

• The latest Fanuc 0iT-D controller 

• Manual guide i conversational programming 

• Exclusive HARTROL productivity software 

www.cncmachine.com.au 

Phone: 1300 CNCSALES or 1300 262 725 


2_AMTIL_010511 

63 

* Specifications & Prices are subject to change without notification. Price excludes GST. Price valid 

from 24th till 27th of May 2011 # Finance is also subject to final credit approval by the financier

Preview 

CMM with reduced measuring time 

It’s all about measurement and quality at the Mitutoyo stand at Austech. 

Mitutoyo exhibits the Mitutoyo CRYSTA-Apex C544 CMM, which offers 

a maximum drive speed of 519mm/s and a maximum acceleration of 

2,309mm/s², resulting in an increase of almost 100mm in drive distance 

in one second without compromising machine accuracy, the exhibitor 

claims. Combining high speed and high acceleration, the CRYSTA-Apex 

C544 dramatically reduces measuring time as the number of measuring 

points increases, resulting in a significant reduction in measuring cost. 

Also on show will be the portable CMM Spin-Arm Apex, a fully flexible 

and portable three-dimensional measuring machine, expanding the measurement 

space and further increasing measurement possibility. Workpieces 

can be measured from any direction and handling is said to be significantly 

improved due to the rotation axis automatic braking mechanism. 

Moreover, the new compact roundness tester RA-1600 is equipped 

with high accurate turntable that enables simple, accurate centering, as 

well as levelling of workpieces to measure roundness and total run-out. 

Mitutoyo - Stand 785 

SEI Carbide exhibits a range of new 

tools 

At Austech, SEI Carbide introduces several new products, including 

the all new WFX 90-degree cutter combined with a new milling 

grade with super ZX coating from Sumitomo. Moreover, the new 

eccentric sleeves WAS type is designed to suit the WDX drill, giving 

manufacturers the possibility to adjust hole sizes through the 

x-axis when drilling. From Big Daishowa exhibitors can see the 

new C Cutter chamfering tool with adjustment from 5 degrees to 

85 degrees in 5 degree increments and the all new alternative R 

cutter with front and back radius cutting. According to SEI Carbide, 

the new unique geometry insert with a high-rake angle features 

reduced cutting forces. 

SEI also exhibits the all new variable helix end-mill with centre 

cutting from Garr Tool, specially designed for titanium, Inconel 

and 17-4 stainless steel. The PCT (polished carbide treatment) is 

claimed to enhance tool life by 20%.The helix geometry varies over 

the length of the flutes and the variable flute design helps chip 

evacuation. 

SEI Carbide Australia Pty Ltd - Stand 567 

www.seiaustralia.com.au 

Seco News: One-stop 

source on new and 

updated products 

Seco will be showcasing a number of new 

products and services during Austech 2011. 

One will be Seco News 2011.1, Seco’s new way 

of introducing new and innovative products. 

This autumn edition contains several new and 

updated products. Seco News ties all the new 

products together in an integrated launch package, 

making it easy to get updated on the latest 

tooling developments and machining techniques, 

from the large diameter, multi tooth XfixTM reamer 

program to new turning and milling grades including 

new Cermet grades for high tolerance finishing applications 

and 2mm MDT. 

Furthermore, Seco has enhanced its PCA program. In 

today’s challenging marketplace it is becoming increasingly 

difficult for manufacturing companies to stay ahead of the 

competition. 

Rising costs are pushing companies into finding other ways 

of saving money and increasing profitability. Seco´s PCA is one 

solution that Seco can implement to enable the measurement, control 

and management of manufacturing processes. 

Seco´s PCA will show where costs can 

be reduced and productivity can be increased 

to help maximise the profit on any process 

within the customers machining facilities. 

According to Seco, customers who use 

Seco´s PCA could typically expect to benefit 

from total cost savings of up to 30% 

and productivity increases of up to 40% 

regardless of the industry sector that 

they are working in. 

To help customers get a competitive 

edge, Seco has developed 

the Seco Point concept. Seco 

Point provides all the means 

machine shops need to 

optimise their stock 

and reduce costs. During 

Austech Seco will 

demonstrate how customers 

can configure the 

information they need and how to cut 

tool consumption costs by up to 10% 

. 

Seco Tools Australia Pty Ltd - Stand 672 

www.secotools.com 



65

Preview 

Maxon motor sets new benchmark with 

brushless 22mm heavy-duty and high 

temp motors 

DC motor drive systems made by Maxon do their job under the most 

difficult conditions, such as, for example, on Mars. But not only in high 

altitudes or in outer space, Maxon DC motors also operate in harsh 

ambient conditions as encountered deep underneath the earth's surface 

– immaculate, dependable, efficient motors. 

As the first manufacturer worldwide, Maxon motor launches with its 

EC 22 HD (Heavy Duty) a standard motor for extremely harsh operating 

conditions. Developed for the exceptionally high requirements in 

deep drilling technology, the electronically commutated motor EC 22 

HD resists even most extreme conditions in which “normal” drives call 

it quits. 

Deep drilling (in the oil and gas exploration industry called ‘downhole 

drilling’) permits exploration of oil and gas resources from depths 

beyond 2500 metres. In conjunction with directional drilling (the dynamic 

orientation of a borehole), it allows exploration of, so far, inaccessible 

deposits in drilling depths of currently about 5,000 metres 

and bore lengths of up to 11,000 metres. Today, electronics and the 

respective drives permit more sophisticated monitoring and control in 

a multitude of functions within the drilling process. 

For instance, the drilling head’s position and orientation can be dynamically 

measured and adjusted. In various deep drilling tools, hydraulic 

valves and flaps are being operated by electro-mechanic drives. 

Temperature and pressure conditions present in this depth range, in 

conjunction with high vibration emitted by the drilling process, make 

the employment of electric drive motors a real challenge. 

The different variants of the brushless EC 22 heavy duty motor are 

designed for operation in air or submerged in oil (flooded in hydraulic 

fluid. Their assigned power rating depends on the surrounding medium 

and averages to 80 Watts in air and, due to remarkably higher heat 

dissipation, 240 Watts in oil. They are designed to cope with ambient 

temperatures of more than 200°C and atmospheric pressures of up to 

1700 bar (25,000 psi). Further requirements of the 22 mm diameter 

motors are the capability to withstand vibration of up to 25 grms as well 

as impulse and impact of up to 100 G, that is 100 times gravitational 

acceleration – as a parallel; a Formula 1 race car encounters about 2 G, 

a fighter jet about 13 G. 

According to Maxon, the motors feature high efficiency (in air up to 

88%, in oil more than 70%) and therefore offer the best prerequisites for 

battery-operated applications. With their detent-free running characteristics, 

they possess outstanding regulation behaviour and are especially 

suitable for high-precision positioning tasks, even at low speed. 

The motor unveils new possibilities in a number of applications that 

call for equally high requirements. According to the exhibitor, it is wellprepared 

for the utilisation in space technology or in power plants as 

well as in vehicle manufacturing, in the aircraft industry, in mining or in 

highly dynamic movements. 

Maxon Motor Australia Pty Ltd - Stand 585 

www.maxonmotor.com.au 

Innovative, technologically advanced tooling and productivity systems 

At Austech, Iscar will display the simplicity of using ISCAR Tool 

Advisor (ITA); calculating parameters such as number of passes, 

speed, feed, power, metal removal rate and cutting time for metal 

cutting operations. Such an important process of tool selection has 

to be made scientifically based on objective and empirical technical 

grounds rather than any conventional intuitive way. By inputting a 

few basic parameters, operators can get accurate cutting data to 

get the maximum productivity and tool life from the tools they are 

using, claims Iscar. 

This product is now also a feature available on the Matrix Series 

4 Tool Management Cabinet and Matrix TM 4.7 software. Iscar will 

have live demonstrations showing how Matrix can save on tooling 

purchasing costs while controlling the issuing and storage of all 

consumable items. 

“Matrix can reduce the time it takes to manage your tooling 

down to a few minutes a day” affirms Greg Reid from Iscar. “Orders 

can be automated and sent direct to suppliers and restocking 

is fast and easy”. Reports and charts can be generated automatically 

to monitor and control usage and get you on the path to lean 

manufacturing. 

Also on display will be ISCAR’S Induction Shrink Unit. Shrink 

technology offers the accuracy and rigidity of a solid tool with the 

flexibility to change the cutting tool in less than 12 seconds, it is 

claimed. A key feature of Iscar’s Induction Shrink is its integrated 

cooling system which cools tools in 60-90 seconds, with minimal 

downtime. While the ability to shrink carbide, HSS and steel, up to 

32mm diameter makes Induction Shrink ideally suited to high speed 

machining, aerospace and mould and die applications, reports Iscar. 

Visit the Iscar stand to go in the draw to win an iPhone 4 each 

afternoon at 3pm. 

Iscar -Stand 668. 




67

Preview 

Restyled machines take centre stage 

At Austech this year John Hart will be exhibiting some of the new range 

of machines from Mazak, which have been released by the Japanese 

machine tool builder since the last Austech in Sydney 2010. According 

to John Hart, the new machines boast increased functionality for 

maximum utilisation 

and return on investment. 

On display will be the all new Integrex j-series, the Vertical Centre 

SMART and Quick Turn SMART. Also on display will be CitizenA32-VII 

sliding head CNC lathe, all under a newly designed stand. The new 

range of Mazak machines has been restyled resulting in a claimed simplified 

setup, greater accessibility to the machining area, convenient 

maintenance, and easier operation. 

According to Mazak, the introduction of the j-400 represents the 

company’s commitment to providing manufacturers with a full range of 

multi-tasking solutions. The Integrex j-Series contains multiple models 

and falls in the middle of the spectrum of Mazak’s multi-tasking innovations. 

The j-400 performs 4-axis simultaneous machining with 5-axis tool tip 

positioning, providing significant advantages in productivity, accuracy and 

flexibility. Unlike multi-tasking machines with a drum turret type, Mazak’s 

Integrex j-400 accommodates 20 tools in a tool magazine (36 and 72-tool 

optional) and increases versatility in part production. The machine’s main 

turning spindle offers a maximum speed of 3300revs/min. 

Live demonstrations will be taking place throughout the exhibition 

and John Hart’s sales engineers will be on hand to provide any information 

about the capabilities and features of these machines as well as 

others in the Mazak and Citizen range. 

John Hart Pty Ltd - Stands 628 and 648 

www.johnhart.com.au 


Cairns 

QUEENSLAND 

Logan City, Queensland: 

A city of opportunities 

Locate your business in Logan City, the gateway to Queensland 

and the Asia Pacifi c region and realise the competitive and 

strategic advantages of our growing economy. 

Brisbane 

Logan City 

Gold Coast 

Adelaide 

Sydney 

Canberra 

Melbourne 

Hobart 

ACCESS 

to markets, staff, 

transport and 

infrastructure. Close 

to the Port of Brisbane, 

Brisbane Airport, Pacific 

Highway, Gateway Motorway, 

Logan Motorway and 

Brisbane-Sydney rail line. 

“A spacious site, an excellent transport 

network and a dedicated local workforce 

allowed Stramit to build a 20,000 sqm factory 

that will supply our needs as well as the 

metal building products needs of South-East 

Queensland for decades to come.” 

- Mark Freeman, 

Region Manager - Northern, Stramit 

“ATCO Structures & Logistics Pty Ltd chose 

Logan City for its Head Offi ce location due 

to its convenient location to critical supply 

chains and the economic advantages beign 

offered. We continue to experience year 

on year growth, taking full advantage of the 

opportunities within Australia and the Asia 

Pacifi c region.” 

- Michael Clennett, 

Executive Vice President, International Business 

Development, ATCO Structures and Logistics 

Contact the Logan Office 

of Economic Development 

for first-hand knowledge of 

current and planned projects, 

market data, site selection, 

development approval 

assistance and government 

funding opportunities. 

OPPORTUNITIES 

in a city of growth with a young, 

vibrant workforce. 

AFFORDABLE 

land, leasing, labour and input costs. 

GROW 

in a city with a 

pro-development attitude. 

CHOOSE 

to live and work in a 

sustainable, idyllic 

environment. 

www.loganbiz.com.au 

www.logan.qld.gov.au/about-logan/economic-development 


OPMENT 

69

Preview 

Roll forming machines 

Sunstra Engineering exhibits a range of roll forming machines and ductwork 

equipment. The company also supplies de-coilers, forming rolls 

and dies. Most of the machines are built to customers’ specification for 

manufacturing different type of products, such as “C” & “Z” purlins, 

steel panels, scaffolding boards, garage door panels, cable trays, various 

tracks and racks, etc. Sunstra provides machines that can handle 

mild steel, medium tensile and high strength carbon steel and stainless 

steel. 

“Based on our customers’ product drawings or sample, we are able 

to provide the optimum suggestion to help our customers to achieve 

the best outcomes,” says Bo Sun from Sunstra Engineering. “Materials 

handling and garage equipment is another strong area of our services. 

We are specialised in design and fabricate custom made products, such 

as pallet inverters, pallet dispensers, special trolleys, high stands, truck 

wheel dollies, machine safety guards and safety cages, etc. “ 

“Our services also include developing a conceptual idea to a proto 

type product or fabricate the products based on customer supplied 

drawings. In addition to that, owing to our rich experience and strong 

knowledge in that field, we can provide repair, modification and maintenance 

services for our valued customers.” 

Sunstra Engineering Pty Ltd - Stand 686 

www.sunstra.com.au 

Precision component manufacturing 

M&S CNC will have on display at Austech 2011 sample components 

from previous projects showing the diverse capability of the company. 

M&S CNC Machining is a family owned precision component manufacturing 

business, committed to supporting and forging lasting relationships 

with its customers through production of high quality CNC 

milled & turned components. 

Incorporated in 1998 the company, dealing mostly with OEM’S, has 

invested significantly in new plant & equipment capable of tackling 2, 3 

& 4-axis milling, as well as 2-axis & multi-axis turning. 

M&S CNC also assist and take responsibility for heat treatment, surface 

finishing / plating, grinding, sub assembly and general manufacturing 

consulting. 

Typically a batch production facility where common runs consist 

of 100-500 parts, supplied to single orders, or on a contract / blanket 

order basis over longer periods of time. 

M&S CNC manufacture for an array of industries some of which include: 

• Telecommunications 

• Medical & scientific 

• Food & beverage 

• Forensic policing 

• Renewable energy & electrical distribution 

• Powder actuated power tooling 

M&S CNC Machining Pty Ltd - Stand MS6 

www.mandscnc.com.au 

Coolant-proof Digimatic Caliper 

For accurate digital caliper readings in the most demanding manufacturing environments, the new IP67 rated Coolant 

Proof Digimatic Caliper from M.T.I. Qualos has been designed to meet the requirements of even the most rigorous of 

applications. 

The new caliper's Ingress Protection (IP) rating of 67 means its housing is sealed dust-tight and has also 

passed a temporary water immersion test proving harmful effects shall not be possible when the enclosure is 

temporarily immersed in water under standardised conditions of pressure and time. IP67 certification also 

means the new digital caliper is dust proof, chip proof, coolant-proof and virtually immune to the toughest 

conditions found on the production floor. According to the company, it can even be submersed in coolant 

and still give the accuracy expected from Mitutoyo (0.01mm resolution with ±0.02mm accuracy 

for the 6" and 8" models). Featuring an absolute linear encoded measuring scale and single battery 

operation with an expected battery life of three years, the caliper is available with optional accessories 

such as IP67 rated data output to suit some models. 

Also being displayed for the first time in Australia is Mitutoyo's new fully flexible portable 

three dimensional measuring device, the SPINARM. An extensive range of Mitutoyo hand 

tools and M.T.I.'s machine tool accessory products will also be on display. 

M.T.I. Qualos Pty Ltd - Stand 635 

www.mtiqualos.com.au 



71

Preview 

A multitude of possibilities with the Faro Laser Scanner Focus3D 

Faro is proud to present its 3D Laser Scanner, Focus3D, at AUSTECH 

2011. According to Faro, Focus3D is a revolutionary, high-performance 

3D laser scanner for detailed measurement and documentation 

with an intuitive touch screen that makes it as easy to operate as a 

digital camera. 

Obtaining accurate as-built documentation is one of the many applications 

of the Focus3D. Common in areas like architecture, civil engineering, 

petrochemical, shipbuilding, and process industries, scanning 

for as-built data before embarking on modifications helps to save 

costs. Capable of scanning objects up to 120m away, the Focus3D is 

suitable across industries — whether on a building, in a plant or on an 

oil rig out in open seas. 

The Focus3D is reportedly able to produce incredibly detailed 

three-dimensional images of complex environments and geometries 

in only a few minutes. The resulting image is an assembly of millions 

of 3D measurement points in colour which provides an exact digital 

reproduction of existing conditions. The light and compact Focus3D 

also deploys an integrated colour camera with automatic and parallaxfree 

colour overlay, allowing photo-realistic 3D scans of up to 70 megapixels. 

Entirely self-contained, the Focus3D does not require any additional 

devices, cables or even laptops. Users are assured of a 

seamless experience from device to computer. All scans done on 

the Focus3D are stored on a SD card, enabling easy and secure data 

transfer. With its dimensions of 24 x 20 x 10cm and a weight of 

just 5.0kg, the Focus3D is so compact and mobile that users can 

take it with them wherever they go. Its integrated lithium-ion highperformance 

battery provides up to five hours of battery life and can 

be charged during operation. 

The Focus3D comes bundled with Faro SCENE software, allowing 

users to manipulate the data collected as desired. The software’s flexible 

interface contains functions such as automatic object recognition, 

positioning and scan registration. As soon as SCENE prepares 

the scan data, users can commence evaluation and further processing 

right away. With its ability to colourise scans, the SCENE is claimed to 

be extremely user-friendly software that generates high-quality output 

in next to no time. The new Web-Share feature allows easy access of 

the laser scans with a standard internet browser. Scan projects can 

now be shared by co-workers via a web server. 

Faro Singapore Pty Ltd - Stand 772 

www.faroasia.com 

Compact heat exchangers 

Celebrating 30 years of providing heat exchangers of the highest 

quality to industry throughout Australia, Fluid Dynamics 

uses the opportunity of the upcoming Austech exhibition to 

showcase its vast range of products. 

On show will be the company’s exclusive FluidEX range of 

compact and versatile shell & tube heat exchangers, which are 

ideal for heat exchange using water as the cooling medium. For 

30 years FluidEX coil coolers have provided excellent service in 

the harshest environments. In the last 10 years, Fluid Dynamics’ 

FluidEX transmission oil coolers have given impeccable service 

to Australia’s famous Bushmaster armoured vehicle in places 

such as Afghanistan. 

For the last 30 years Fluid Dynamics has also been the exclusive 

Australian dealer for Germany’s famous AKG aluminium 

core marketed by Fluid Dynamics under the FluidAIR label. According 

to the exhibitor, Fluid Dynamics is the only company 

in the world entrusted by AKG to manufacture its core into the 

highest quality aluminium core heat exchangers available. Ask 

us about our range of oil coolers and charge air coolers available 

with or without fans. 

Fluid Dynamics can custom-build to customers’ dimensions and 

replace almost any aluminium core cooler but also carries stock 

coolers for quick delivery. Fluid Dynamics is also expert in testing 

repairing and rebuilding a wide range of large industrial heat exchangers 

found in power stations, ships and larger industrial installations. 

Fluid Dynamics Pty Ltd - Stand 795 

www.fluiddynamics.com.au 


Preview 

From nano technology to heavy 

engineering 

Realtek Technologies will exhibit a broad range of advanced technologies 

from nano-machining and fabrication, micro-machining and 

moulding to large scale heavy engineering at AUSTECH 2011. The company 

services the medical devices sector, mining and energy, automotive 

and aerospace. 

Realtek will have the following machines on display: 

• A world class VMC from Toyoda, Japan 

• FV1050S Vertical machines 

• 1500 rpm Spindle 

• Fanuc 18imb 

• 36 m/min Rapid Travel 

• 40 Tool ATC 

• BT40 

• X, Y, Z Travel 1020 x 510 x 510 

• SR20RIII CNC Swiss Type Star Micronics automatic turning centre 

with motion control system and a Fanuc 300i controller system with 

ALPS ASRX20P bar-loader 

• world -eading filtering systems 

• Fox IFS - from Europe models WS500 & WS1000 

• Nanotech 

• PVATePla Plasma System. 

• Vacuum and atmospheric plasma cleaning and surface preparation. 

Realtek Technologies Pty Ltd 

Realtek Australia - Stand 694 


Affordable technology for the entire 

production line 

Headland will have a large stand of over 400 square metres to 

showcase their specialty machinery in the areas of sheetmetal, 

laser and bending machines, fabrication, waterjet, punch and 

shear machines, bandsaws and drills. Moreover, vertical storage 

systems, 5-axis CNC machining centres, new controllers and 

large payload robots will be on show. 

Headland will be holding intimate breakfast seminars for each 

of their divisions. To register please email marketing@headland. 

com.au. During the show, demonstrations will be held throughout 

the day with international and local experts available to talk to you 

about improving the efficiency of your factory. 

“We look forward to a great show and an opportunity to showcase 

the new and affordable technology we have to offer manufacturers 

for their entire production line,” says Headland’s Annaliese 

Kloe. “We’ll also be talking to visitors about our ongoing 

service and support.” 

Headland Machinery Pty Ltd - Stands 750 and 748 

www.headland.com.au 

Cost Effective. 

Prime Position. 

Greater Frequency. 

Strip ads are back! 

Call Anne Samuelsson at AMTIL 

on 03 9800 3666 for more info. 


RN8589 

73

Cutting Tools 

Cutting tales 

Improved productivity through the application of latest tooling innovations has been achieved by 

three companies: one in the UK, another in Germany and a third in Jordan 

B y A n d r e w A l l c o c k 

ith a view to streamlining its cutting tool ordering 

system, reducing inventory levels and cutting tool 

use, Benham Manufacturing undertook a review of its approach 

to tooling. 

Founded in 1978 as DA Benham Engineering, as a supplier 

of components for the communications industry, the 

company made the strategic purchase of a precision engineering 

company in 1995. Three years later, the two businesses 

merged and moved to purpose-built manufacturing 

facilities on the edge of the New Forest England. 

To keep pace with the growing demand for its now mainly 

aerospace related output, the family-owned business recently 

added three advanced Mazak 5-axis machining centres, with 

pallet loading and gun drilling capability, to its plant list. 

In support of the tooling initiative, a series of criteria 

was established. Iscar products were judged against those 

of competitors, in terms of speed, tool life, unit price and 

time advantages, with the results translated into both machining 

costs and actual savings per part. On completion, 

the project delivered a number of conclusions, one being 

the advantages that could be gained by increased use of 

Iscar cutting tools. 

Walter's Tiger.tec Silver CVD-coated tooling inserts are helping 

MSB tackle its long milling routines successfully 

Walter at MSB, tackling a machine tool bed 

Iscar's Matrix tools store system is in use at Benham 

Manufacturing, saving money 

Flexibility cuts categories 

The flexibility of Iscar's products has resulted in Benham 

Manufacturing significantly reducing the categories of tools 

used. Faster cycle times, due to improved tool selection, 

have resulted in increased machine tool productivity. Furthermore, 

the company's overall cost of purchasing cutting 

tools has been reduced. 

A major factor in reduced machine downtime has been 

the adoption of Iscar's Matrix tools store system. Managed 

by a local Iscar distributor, Matrix is a computerised total 

management system that gives users control over their 

cutting tool inventory, streamlines purchasing functions 

and drives down costs. Access to an item stored within 

the system's locked bins is electronically controlled, with 

entry determined by the establishment of pre-defined 

authorisations. 

"Having made the decision to review our tooling organisation 

and use, we found the help given to us by Iscar 

extremely useful," says Paul Benham, Benham Manufacturing 

Managing Director. "Our aim was to take any previous, 


Cutting Tools 

subjective perceptions out of our tooling choices, removing 

them from the production equation. Although a previous 

enthusiastic user of Iscar cutting tools, I was delighted 

by the findings of our trials. Given the on-going need to 

deliver high quality components at the best possible price 

to our customers, our increased use of Iscar cutting tools 

and their Matrix system has enabled us to further improve 

our competitiveness. 

"Our implementation of Iscar's Matrix, computerised 

tool storage system has streamlined the company's cutting 

tool operation, while, at the same time, considerably 

improving our productivity. As our local supplier regularly 

replenishes the Matrix system, out-of-stock situations have 

been eliminated, while substantial man hours have also been 

saved on our previously used regime of manual tooling stock 

checks and ordering." 

In Germany, at MSB, Bavaria, Walter's innovative Tiger. 

tec Silver CVD-coated tooling inserts are extending tool life 

by at least two-fold – and consequently reducing machine 

downtime for insert changes, as well as cycle times – for the 

company that specialises in the manufacture of mechanical 

engineering workpieces. 

Indeed, not only is the use of WKP35S inserts in a 

125mm diameter Walter F2010 milling cutter boosting insert 

edge life from 18m to 36m as a minimum, but the groundbreaking 

tooling is also enabling the company to increase 

cutting speeds on its large, 65kW portal milling machine 

by 20% (from 236m/min to 283m/min) and hoist feed rates 

(from 1,584mm/min to 2000mm/min). The machine processes 

workpieces that traditionally spend 50 to 100 hours 

having tonnes of swarf removed. 

Capable of fabricating components weighing 30 tonnes 

and undertaking milling routines on workpieces 14 m long, 

MSB has used Walter's tooling system supply strategy for 

some time – sourcing milling cutters, drills and taps, for 

example. 

These are used in its one-off and low-batch manufacture 

of workpiece feed and storage systems, pallet change and 

pallet clamping systems, and spindle and milling head change 

systems, for instance. An associate company also produces 

machines and conveyor systems for the tunnelling and mining 

sectors. Technical Manager Wolfgang Faust explains: 

"We used the previous version of the Walter tool, because 

it was one of the best products on the market – and Tiger. 

tec Silver represents a further quantum leap. The higher 

cutting efficiency ultimately enables us to reduce the costs 

of the end product." 

Farther afield, Jordan-based Jordan Advanced Machining 

Company (JordanAMCO) slashed production 

time on a project by half, after receiving assistance from 

Dormer Tools International – Dormer's export-arm, based 

at the Advanced Manufacturing Park in South Yorkshire, 

England. 

Machining hundreds of 20.25mm diameter holes in 

heat exchanger plates used in the petroleum industry, 

JordanAMCO required a versatile solution that could 

not only drill at various depths and increase productivity, 

but also maintain tight tolerances and strict quality 

requirements. 

Dormer supplied its Hydra drill – a replaceable solid 

carbide head (R950) and interchangeable HSS body. With 

JordanAMCO required a versatile solution that could not 

only drill at various depths and increase productivity, but also 

maintain tight tolerances and strict quality requirements 

JordanAMCO stack-drilling four 10mm carbon steel plates 

and also needing to drill 75mm through-holes, Dormer 

supplied 3xD (H853) and 5xD (H858) Hydra bodies. Lloyd 

Allen is technical consultant for JordanAMCO and advises 

the company's management and engineers. Originally from 

Rotherham, South Yorkshire, Mr Allen, explains: "The 

boiler plates provided difficult cutting conditions, because 

of the material type. It wasn't easy to get the swarf to chip 

correctly. 

"With high speed steel tooling, it would have taken 

around 18 hours to complete the job, but with Dormer's 

Hydra drill it took just eight hours. 

"It also removed the need for additional operations, such 

as reaming, resulting in further time and cost savings." 

JordanAMCO, initially set up in 2007 to advance Jordan's 

manufacturing capabilities, is now expanding not just 

throughout the Jordan area, but is also securing projects in 

Europe, America, The Gulf and Saudi Arabia. 

"Manufacturing in Jordan is still in the early stages and 

the role of JordanAMCO is to help develop the industry 

further," Lloyd explains. "As well as providing machining 

services on a direct supply basis, JordanAMCO also provides 

technical assistance to other local manufacturers with 

tooling selection, heat treatment, training requirements, and 

assistance with the understanding of material properties 

and their machining characteristics." 

A key ingredient of the success is the support provided 

by Dormer. James Butler, Dormer Technical Engineer, 

explains: "We first made contact with the owners soon 

after the company was established and our partnership has 

progressed over the last couple of years. 

"The Hydra drill is well proven, with documented successes 

in heat exchanger applications around the world. 

JordanAMCO's experience is one more that we can add to 

this growing list." 

First published in Machinery, August 2010 


75

Cutting Tools 

Avalon Airshow 2011 a huge 

success for Sandvik Coromant 

rganisers of the Avalon Australian 

International Airshow 2011 

have been delighted with a this year’s 

event, with more than 180,000 visitors 

from 1 to 6 March 2011. 

While good weather, a fantastic 

line-up of aircraft, along with all 

the celebrations associated with the 

RAAF 90th anniversary has contributed 

to an outstanding event, many 

Australian aerospace and defence 

suppliers used the opportunity to 

showcase their products and capabilities. 

One such company was Sandvik 

Coromant, who exhibited within the 

Australian International Aerospace & 

Defence Exposition, the centrepiece 

of Avalon 2011. 

As the world’s largest producer of 

cemented carbide cutting tools and 

tooling systems for the metalworking 

industry, Sandvik Coromant has a 

strong focus on the Aerospace sector. 

As such, it used its impressive 27m² 

stand to display an extensive range 

of tooling and solutions developed 

specially for this sector. These included machining solutions 

for composite materials. Sandvik also used the show 

to introduce a range of drills used for rivet and bolt holes 

in carbon reinforced plastics and metallic stack materials. 

“Aerospace is one of the most technically demanding 

industries in the world,” says Greg Bennet, National Sales 

Manager Aerospace, Sandvik Coromant Australia. “Our 

goal is to offer complete solutions for our customers in this 

sector, not only the physical tools, but also the processing 

knowledge to increase productivity in the manufacture of 

aerospace parts made from difficult-to-machine materials 

including titanium and composites.” 

“Each carbon fibre material has its own demands, which 

increases the risk for delamination or Fibre Breakout,” he 

continues. “Our new CoroDrill 452 geometries reduce this 

risk, ensuring the stringent hole tolerances are met with 

exceptional finish and quality.” 

The range includes reamer geometries and a countersink 

tool with microstop for chamfering – and it comes at the 

right time when Australia’s demand for aerospace parts 

is booming and the industry is gearing up its composites 

machining capacities with the extension of the Cooperative 

Research Centre for Advanced Composite Structures 

(CRC-ACS) in Melbourne, coincident with the International 

Airshow. 

CRC-ACS CEO Prof. Murray Scott believes strongly 

in the role of technology development and international 

engagement in securing Australia's future aerospace and 

defence industry. "It is clear that Australia views a healthy 

local aerospace and defence industry 

as a key part of its future 

prosperity, and Australia is winning 

major contracts in civil and 

defence aerospace. CRC-ACS has 

had a pivotal role in technology 

development for this industry. We 

are now moving through an exciting 

new phase, where Australian 

industry is working directly with 

international organisations in a 

research program focussed on 

Australia.” 

While the CRC-ACS Extension 

Program was formally 

launched during the International 

Airshow, other major aerospace 

and defence contracts were signed 

as well, including BAE Systems’ 

and Marand’s $790m long-term 

agreement for the supply of vertical 

tails for the F-35 Joint Strike 

Fighter. The company will be the 

in-country lead for the manufacture 

of 722 vertical tail fins, and 

will undertake final assembly of 

titanium components being machined by BAE Systems 

Australia in Adelaide. 

BAE Systems Group Managing Director – International, 

Guy Griffiths believes that this long term agreement will 

bring more work into Australia. “It underscores not only our 

confidence in the F-35 program but also in our continuing 

relationship with Marand. I would like to emphasise our 

company’s commitment to developing the Australian supply 

chain for the F-35 program.” 

In order to secure aerospace suppliers’ leading edge 

capabilities, they need reliable technology partners. BAE 

Systems in Adelaide looks back at a long-standing relationship 

with Sandvik Coromant, and visiting the Coromant 

stand during the Airshow, BAE Systems’ General Manager 

Land Systems & Manufacturing, Jim Hanson, reinforced 

the company’s commitment to work with the Sweden-based 

cutting tool supplier, offering local support with global 

strength and expertise. 

Sandvik Coromant Australia is dedicated to the aerospace 

industry in this country and Mr Bennett believes that huge 

opportunities exist with the industry moving forward with 

contracts including the JSF, Eurocopter or the Boeing 

Dreamliner 787. “Avalon 2011 was a successful show for 

us and everyone visiting our stand was extremely positive, 

I think it was a good show,” says Colin Fairbank. “It demonstrates 

our investment in this growing industry. 

Colin Fairbank, Sandvik (left), explains Sandvik 

Coromant’s extensive range of tooling solutions 

for aerospace applications. 

Sandvik Coromant Australia Pty Ltd - 03 9238 7163 

www.coromant.sandvik.com/au 


Cutting Tools 

Theory and practice, hand in hand 

Walter and the West Saxon University of Applied Sciences of Zwickau Germany benefit 

from close cooperation 

s an expert leader in machining, regular cooperation 

with the scientific community is very important to 

Walter. In addition to cooperation with numerous other 

universities, the precision tool specialist has already been 

working closely with the West Saxon University of Applied 

Sciences of Zwickau Germany for more than ten years. This 

gives students valuable insights into the practical application 

of their knowledge, and Walter uses the results to develop 

new products and technologies. 

One focus of the co-operation is the development and 

testing of tools for complete machining of turbine blades for 

the energy industry. With its Institute for Production Engineering, 

the university has excellent practical expertise in 

this area in particular. Walter is working with the university 

as part of projects with other companies, but also regularly 

assigns its own orders to the Institute. This includes student 

projects and diploma theses. Walter provides the university 

with the necessary tools. 

"In addition to support in the form of tools, our students 

benefit from co-operation with one of the leading tool 

companies in the sector, thanks to close and fruitful cooperation 

with Walter's experts", says Prof. Dr. sc. techn. 

Michael Schneeweiß, head of science at the Institute for 

Production Engineering at the West Saxon University of 

Applied Sciences of Zwickau. 

"By means of these practical projects, co-operation with 

Walter helps us prepare the students for the challenges of 

the industry." 

Walter assigns two to three orders to the university 

every year. The range of topics to be dealt with is diverse - 

from five-axle machining, NC programming, determining 

power and performance, developing new component-based 

strategies for roughing and finishing to machining tests that 

accompany tool development and determining guideline 

values for newly-developed tools. Tools belonging to the 

three key Walter brands - Walter, Walter Titex and Walter 

Prototyp - are used in the projects. 

"As an expert leader in machining, close cooperation 

with the scientific community is essential", says Andreas 

Elenz, Energy Branch Manager at Walter AG. "They provide 

us with important stimuli for developing new technologies 

and tools. We are linked to the West Saxon University of 

Applied Sciences of Zwickau by particularly close cooperation 

that has lasted many years. Both sides benefit from 

this co-operation." 

The West Saxon University of Applied Sciences of 

Zwickau is currently working on three orders from Walter: 

two projects from the energy department and one from 

development. 

Walter Australia Pty Ltd - 03 8793 1000 

service.au@walter-tools.com 


When a customer 

blade is machined, 

approximately 

85% of the 

volume of the 

un-machined part 

is machined away. 

The complete 

manufacturing 

process takes 

95 minutes. 

Image: West 

Saxon University 

of Applied 

Sciences 

BelmaticAMT.qxd:ManMon 5/10/10 2:28 of PM Zwickau Page 1 

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Ask Belmatic to provide the ideal solution for your needs. 

Belmatic Industries Pty Ltd 

12 Kylta Rd, Heidelberg West VIC 3081 

P: 03 9459 8097 

W: www.belmatic.com.au 

APPLIED FASTENER COATINGS • SPECIALISED PRECISION ENGINEERING 


77

WHEN NO ONE CAN MEASURE IT 

WE CAN. 

Cutting Tools 

Multi-Master – ten 

Electronic Snap Gauge 

Range: 0-12.7mm 

 

Resolution: .0005"/.02mm 

 

Inch/mm reading 

 

Auto off 

 

Zero at any position 

 

Bench-Top Optical Projector 

400mm Screen Diameter 

 

254mm x 100mm measuring travel 

 

Fiber optic surface illumination 

 

Electronic Depth Gauge 

Graduation: 0.0005"/ 0.01mm 

 

Hardened stainless steel body & slide 

 

Fine adjustment thumb wheel 

 

Instant inch/mm conversion 

 

www.starrett.com.au 02 9620 6944 

Contact us for details of your local distributor 

n 2000 Iscar introduced the Multi-Master – a family of 

rotating tools, comprising mainly milling cutters, with 

interchangeable solid carbide heads. Now, 10 years later, the 

family has a strong presence in industry. In Multi-Master, 

a solid carbide head is connected with a tool body (shank) 

by a specially shaped thread. The success of the thread 

connection, produced directly on a solid carbide part, has 

changed pre-existing views of such an approach. 

In accordance with the Multi-Master concept, one shank 

can carry the heads of different cutting shapes. This concept 

considerably increases versatility and functionality of the 

family, significantly reduces demands for specially tailored 

tools and allows the customer to decrease his stock of cutting 

tools. Additionally there is no requirement for regrinds. 

So how exactly is the head mounted to the shank Well, 

the head has two surfaces: a short taper and a rear noncutting 

face that determines its precise location. The taper 

ensures that a high degree of concentricity is maintained, 

while the thread simply secures it against the back shoulder 

of the shank. During mounting, the head is initially rotated 

by hand and then is tightened by means of a key. The head 

has flats for applying a key. 

The advantage of having the face contact is that it considerably 

increases the stiffness of an assembled tool and its 

ability to withstand impact loading so common in milling. 

According to Iscar, this factor allows for stable cutting, 

minimises vibrations and reduces power consumption. 

The face contact also ensures high repeatability of the 

head overhang with respect to the shank. As a result, there 

is no need for an additional adjustment after replacing the 

head - no setup time – and an operator can change the head 

without removing the shank from a machine tool spindle. 

When tightening a head, an operator starts by rotating 

the head by hand. The head then stops at some point and 

a small gap remains between the contact faces of the head 

and the shank. From this moment further head tightening is 

only possible using the key. Tightening of the head causes 

elastic deformation of the adjoining contact area of the shank 


Cutting Tools 

years of service and still going strong 

section, in a radial direction. The gap is called ‘initial’; and 

is an important feature of the Multi-Master connection. 

The gap value is several tenths of a millimeter, depending 

on the thread size. 

The Multi-Master threads require a special ‘T-thread’profile 

chiefly because the brittle nature of tungsten carbide and the 

load it has to bear in relation to its size. Minimising stress 

concentrators is one of the main problems to be solved when 

designing a threaded tungsten carbide part. 

What types of multi-master heads does Iscar offer 

Iscar offers a number of Multi-Master heads, firstly, the 

milling heads: 

• End milling heads of various shapes – 90°, 45°, 60°, etc. 

– ball nose, toroidal, concave radii, heads for high-feed 

milling 

• Slotting and grooving heads for milling grooves for 

retaining or O-rings, T-slots, etc. 

• Threadmilling heads 

• Centre drilling heads 

Like all tooling, the number of teeth and cutting geometry 

is determined according to the application. For example, in 

finishing and milling hard materials, increasing the number 

of flutes makes cutting more stable and productive. 

Iscar offer heads in two categories, the first type are 

produced from stepped cylindrical blanks by grinding. The 

other type is sintered with a small oversize and then ground 

to define the final shape of a head. Heads of this type have 

a high-strength tooth, making it possible to increase the 

feed-per-tooth in comparison to the solid ground type. The 

economy, sintered-type heads have only two teeth. 

So what is the accuracy of the heads The nominal diameter 

of the normal accuracy endmilling heads has the following 

tolerance limits: e8 for multi-flute heads produced from 

blanks and h9 for the economy type heads. The precise heads 

for finish profiling are made with tolerance limits for diameter 

h7 and the heads for milling aluminum – h6. The diametric 

tolerance for the cylindrical cutting area of the heads 

for chamfering, spot drilling and countersinking is h10. 

Iscar Australia Pty Ltd - 02 8848-3500 


JBO BGFS drill 

thread milling cutter 

he new tool design can be used for 

drilling and threading in steel, stainless 

steel, titanium and nickel based super-alloys such as 

Hastelloy, Inconel. Because the BGFS creates the thread 

and the core hole in one operation by interpolation you‘ll 

never have a problem with long chips. The internal 

coolant carries away swarf during use. The company 

has built two different types, the BGFS-W 8 (2xD and 

3xD, M6-M16) usable for threading in steels up to 

1200 N/mm². The BGFS-H design (2xD, M6-M16) can 

be used in hardened material up to 63 HRC providing 

there is no dust is in the thread after hardening and no 

misalignment. 

The tools are available for threads up to 2xD for 

metric and fine pitch thread and can be purchased in UN, 

UNC, UNF and UNJF thread forms and coated. 

MD ProductionTechnology - 02 6026 4956 

markus@mdprotec.com 

www.mdprotec.com 

6 LOBE BLANKS 


79

Cutting Tools 

Improving economics for machining 

cavities in hardened steel 

As a mould manufacturer, Minco improved its cavity hogging and reduced bottlenecks in a key 

operation on a popular hardened stock with a facemill featuring three flutes with six-sided inserts. 

B y K e n C l a c k a n d G l e n M u l l i n s 

inco’s cavity hogging test on hardened 15-5 PH mould 

stock showed two exceptions that prove the rule. First, 

the old rule of thumb that tooling typically represents less 

than 3% of total tooling cost doesn’t necessarily apply to 

hard metal machining. When the operation was optimised 

with a TaeguTec milling cutter, tooling previously represented 

more than 30% of the total machining cost. Secondly, 

although that cutter ran 10% slower than a competitor, it 

actually proved more cost-effective. Much lower tooling 

costs more than offset the gap in speed. Want to improve 

process economics for roughing mould cavities in hardened 

stock Take a tip from Minco Tool and Mould Inc., which 

capitalised on an “exception that proves the rule” in machining 

tooling economics—and saved handsomely as a result. 

With 85 employees, the Dayton, US, mould and die maker 

operates 24/5 or 24/7, depending on volume. 

The operation at issue is rough milling of mould cavities/ 

cores in an increasingly popular mould stock, 15-5 PH stainless 

steel hardened to Rc40. The alloy owes its popularity 

to excellent corrosion resistance and the high surface polish 

that can be achieved at the finishing stage. But back at the 

roughing stage, unfortunately, it’s a bear. It’s abrasive and 

gummy, and really heats up during cavity roughing, which 

often leads to sudden cratering failures at the cutting edge. 

For that reason, Minco couldn’t risk running the operation 

unattended. 

The free cutting TaeguTec mill ran at lower temperatures 

in hardened 15-5 PH steel in Minco tests. Insert 

geometry ensures that most of the heat goes into the chip, 

which keeps the workpiece itself cooler. Cooler running 

eliminated cratering-type insert failures that plagued the 

operation before. 

Minco’s presenting problem 

The retooling effort began when Mullins headed up Minco’s 

effort to clear up this bottleneck operation on such a promising 

mould cavity/core material. The original tooling was 

a four-flute indexable face mill, with each insert providing 

three edges. It had worked fine on a variety of other metals 

that Minco runs, but not on hardened 15-5 PH. Even when 

process engineers lowered the feedrate and took a shallower 

cut, the operation still ran too slow and wrecked too many 

inserts prematurely-and unpredictably-due to edge cratering. 

“We could have lived with the lower removal rate, but 

not the insert replacement costs,” says Mullins. Contributing 

to the expense was the fact that cratering on a single edge 

often rendered the entire insert worthless. “If the failure 

mode were edge wear, we could simply index the insert 

because the other edges would still be good,” he explains. 

“Not so with cratering-type failures.” 

When rules of thumb don’t apply 

What rule What exception A familiar rule of thumb says 

that on a typical machining job, machining and labour time 

represent about 75% of total part cost, with tooling accounting 

for only about 3 to 5%. “That rule may apply for production 

parts in softer steels and nonferrous metals,” says Glen 

Mullins, Minco Procurement Manager. “One key exception, 

though, is hard metal machining, where the balance shifts 

significantly. In fact, for cavity roughing this hardened 15 5 

PH stock, the tooling that proved optimal represented more 

than one third of total machining cost.” 

Surprisingly, the facemill of choice for this punishing 

job, a TaeguTec mill, wasn’t even the fastest, though it came 

close within 10%. But its tooling cost proved to be two thirds 

lower than the nearest competitor, which in dollar terms 

more than offset the small gap in speed. 



81

Cutting Tools 

deep Test criteria included tool geometry, feed, speed, depthof-cut, 

chip load, stepover, spindle load, volume of material 

removed, cycle time and tooling cost. All tests were run on 

the same vertical CNC machining centre. 

Minco’s original cutter was a zero-rake, four-flute design 

with 3-sided inserts. One of the finalists used five 4-sided 

inserts, and the TaeguTec mill featured just three flutes 

with six-sided inserts. 

Rivals in the room 

To find a best-practice solution, Mullins gathered a crosssection 

of leading tooling supply companies together in the 

same room, presented the challenge and invited them to give 

it their best shots. Invited were companies already supplying 

Minco, plus several others. “Putting them all in the room at 

once, I think, helped produce a better answer sooner,” Mullins 

says. “We cast a pretty wide net here because we believed 

that the 15-5 PH material showed great promise over the long 

term,” Mullins adds. “Optimising the roughing operation once 

and for all for that material would be well worth the effort.” 

Two-step evaluation process 

All were invited to demo their tooling-once. Then Mullins 

and Ed Draper, CNC Manager, narrowed the field to two 

finalists, and ran comparative tests of their own design on 

identical cavity blocks of the actual hardened stock. 

The sample blocks measured 6.00 x 12.50 x 19.50in. 

(152.4 X 317.5 X 495.5mm) with two cavities 4.000 inches 

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Test cuts 

Recent tests at TaeguTec demonstrated that the TaeguTec 

mill can handle plunge milling as well as roughing. A 3-inch, 

(76.2mm) 5-flute cutter in a Hardinge Bridgeport 30-hp VMC 

roughed a 2-inch (50.8mm) deep slot through 4140 steel at 

18ipm (457mm/min) with 0.275-inch (6.98mm) stepovers. 

Throughout the test, cutting action remained quiet and 

smooth and the spindle power gauge never went above 60%. 

At the end of the cut, inserts showed no discernable wear. 

General lessons from confidential tests 

Minco regards actual times, machine settings and costs 

as confidential, but offered some general findings showing 

how sometimes the exception proves the rule. Both 

finalists finished the blocks in half the time as the original 

tool, with the 5-flute cutter completing the cavities about 

four minutes faster than the TaeguTec mill. But because 

the TaeguTec three-flute mill used only three inserts, each 

with six edges, its tooling cost was lower by nearly 70%. 

Furthermore, in the winning case, tooling cost was 35% of 

total machining cost, more than 10 times higher than the 

general machining rule of thumb. 

Helical cutting edge on TaeguTec milling insert eases 

into the material, like scissors shearing paper. This reduces 

the shock and impact as the insert enters the workpiece. 

Although the three inserts on the TaeguTec mill each 

face a higher chip-load than the five on the other, the Taegu- 

Tec inserts lasted longer because of two key differences in 

geometry at the cutting edge: higher positive rake and the 

helical geometry. The higher rake reduces cutting forces 

while the helical edge reduces shock and impact as the insert 

enters the hardened material. 

“The harder the workpiece material, the greater the benefit 

of free cutting geometries and helical edges,” explains Ken 

Clack, TaeguTec field Engineer who assisted with Minco’s 

retooling. “Positive rake creates a cleaving action at the 

cutting edge, rather than scraping. With the helical edge, 

the insert enters the material a little at a time, like scissors 

shearing paper.” 

The freer cutting geometry also reduced residual heat 

in the mould blocks, the root cause of those catastrophic 

cratering failures in the original tooling. “That geometry 

also puts more of the machining heat into the chip, leaving 

less into the workpiece,” says Clack. 

Potential for unattended operation 

In fact, now that Minco has standardized on the TaeguTec 

mill for this roughing operation, the process has proven 

secure enough to run unattended. “With edge wear rather 

than cratering as the edge failure mechanism, we can predict 

edge life reliably, and schedule indexings accordingly.” 

says Draper. 

TaeguTec Australia - 1300 823 48832 

www.taegutec.com 


Going to new depths 

he second of Dormer’s annual ‘D.Pack’ product launches 

features a key addition to their solid carbide application 

drilling range.Spearheading the company’s continued 

expansion into the high performance deep hole drilling 

market are three new tools capable of supporting ‘one-hit’ 

drilling to depths up to 30xØ. Branded Elect APP, the 

R572 (15xØ), R573 (20xØ) and R575 (30xØ) complement 

the existing R570 (8xØ) and R571 (12xØ) drills. 

All drills feature ACM (Advanced Chip Management) 

flute geometry that not only provides ample flute volume but 

also encourages the production of small, easily evacuated 

chips to minimise machine downtime. 

Dormer’s proprietary Super-Flow coating has been specifically 

developed to optimise the performance capabilities of the 

Elect APP drills for deep holes. As such, it offers a host of 

benefits including greater stability of cutting edges, outstanding 

wear resistance and significantly increased productivity. 

Although both are significant features in their own right, 

they combine to even greater effect as David Goulbourne, 

Dormer’s development manager for drilling products, explains; 

“these two elements work together to ensure consistent 

forces throughout the drilling cycle with little or 

no increase in the torque generated as the drill penetrates 

deeper into the hole. The end result is a drill that can run 

faster, for longer.” 

Dormer’s patented double offset margin ensures that 

increased performance and tool life does not, however, 

Cutting Tools 

Dormer’s R575 is capable of drilling to 30xD without pecking 

come at the expense of quality. This unique feature provides 

greater stability to the drilling operation with subsequent 

reduction in chatter and improved hole concentricity. 

The Elect APP drills for deep holes all provide exceptional 

levels of performance in a wide range of materials 

including steel, stainless steel, cast iron and aluminium. 

The product launch is supported by a comprehensive 

brochure that includes full range details and optimum operating 

conditions in key deep hole drilling applications, 

including cross hole and angled face drilling. 

Dormer Tools - 0418 966 951 

www.dormertools.com 

Machining Solutions 

Intelligent Design 

• Micro Precision CNC milling 

and Cylindrical grinding 

• High speed CNC machining 

• 3 axis EDM CNC machining 

• CNC wire cutting 

• 3 axis CNC turning 

Measurement 

• World acclaimed CAD, CAM software 

• In house product and development 

• In house mould design 

• Specializing in the manufacture of high 

speed Liquid Silicone Rubber moulds 

and Plastic Injection moulds 

• Turnkey Solutions including Robotic de 

moulding. 

• Precision machining of all materials 

• CMM metrology with virtual 

3D CAD model comparison 

• Non Contact Optical measuring 

10 Binney Road, Kings Park, 

NSW 2148 Australia Tel: +61 2 9621 5900 

F +61 2 9621 5966 

Bennett Precision Tooling Pty Ltd 

www.bptooling.com.au 


83

Motors & Drives 

Direct drives for cooling 

tower applications 

mprovements in system safety, 

reliability, efficiency and noise 

reduction are now possible with the 

introduction of new VS1CTD PM motor 

and drive technology applied to 

cooling tower applications. The same 

electric motor and control technology 

that is being used to power today’s 

most hybrid vehicles is now being 

adapted for cooling tower drive applications. 

Advances in motor power 

density using laminated steel frame 

construction combined with high flux 

strength permanent magnet salient 

pole rotor technology results in a high 

torque, slow speed, low profile motor 

that is mounted directly to the fan and 

operates at variable speed to maximise 

system efficiency. 

Permanent Magnet Rotor (PMR) 

construction using high flux strength 

Neodymium Iron Boron (NdFeB) magnets 

allows the motor to be manufactured 

in a compact form factor. The 

same basic motor design requirements 

for a hybrid vehicle of high torque, 

efficient, low weight, reliable, quite 

and highly compact also apply to the 

cooling tower application. 

For the past 20 years, Rod Applegate, 

the owner and president of Tower 

Engineering, Inc., has been earching 

for a better method of driving fans in 

cooling towers. He says he has finally 

found what he’s been looking for in 

Baldor’s new RPM AC® cooling tower 

direct drive motor controlled by a 

Baldor VS1 cooling tower drive. Applegate 

predicts that five years from 

now this solution will be the norm. 

His company is already installing 

these motors in new cooling tower 

construction. He also believes this is 

an ideal solution for existing cooling 

towers. “We will be doing as many 

retro-fits as we can because they’re 

just so darn easy,” says Applegate. 

“The Baldor engineers were smart 

enough to create a low profile motor 

design that fits in the same space and 

mounting footprint as the gearbox. It’s 

so simple; it’s almost just a drop-in 

replacement.” 

Over the past 20 years, Applegate 

has seen potential cooling tower fan 

drive solutions come and go, with 

none working any better than the gearbox 

drive train design. But this time 

he’s convinced he’s found a superior 

performing, user friendly and green 

solution. “I am confident that this is 

a real and permanent solution for the 

industry,” says Applegate. “My confidence 

was strengthened after meeting 

and getting to know the engineers who 

designed and worked on the project. 

I was constantly blown away by their 



intelligence. I’ve also visited the plant 

and watched the product being manufactured. 

This is a company that will 

stand behind the product, that’s why 

I know it will be a success.” 

Since April 2008, Baldor has installed 

close to 100 units at a variety 

of users, ranging from universities 

and hospitals to data centres, small 

manufacturing locations and refineries. 

“This is very new technology 

and has allowed Baldor Australia to 

tender for projects in an industry that 

we were not previously involved in,” 

says Applegate. 

A couple of years ago when a Baldor 

Dodge engineer called on Tower 

Engineering to discuss gearboxes, it 

was explained, in no uncertain terms, 

that they didn’t need another gearbox, 

what they needed was a direct drive 

fan motor. This engineer took the 

message back to his superior, where it 

was determined that this was a project 

that Baldor would take on. After extensive 

Lab testing at Baldor’s facility, 

motor and drive systems have been 

installed and field tested for as long 

as three years. One system is running 

under a controlled environment on 

one of two identical cooling towers 

at Clemson University. Both towers 

were instrumented and the traditional 

geared system was compared to the 

one converted to use Baldor’s Adjustable 

Speed Direct Drive Motor and 

Drive System. Each tower had the 

same 5 blade 18 foot (5.5m) diameter 

fan. The conversion was made in 

less than a day. Performance results, 

which were verified by a third party, 

measured an input kW power savings 

of 11.8% compared to a tradional 

geared system, with high speed noise 

reduction from 82.3dBA to 74.fdBA 

and reduced vibration. 

The result of the research and 

development is the Baldor-Reliance 

RPM AC Cooling Tower Direct Drive 

Motor, which features a power dense, 

laminated steel, finned-frame construction. 

A proprietary Permanent 

Magnet Rotor (PMR) design using 

high-flux magnets allows the motor to 

be manufactured in a compact form, 

similar to the gearbox it replaces. 

Baldor Australia has serviced local 

industry for more than 25 years, providing 

fast access to the extensive product 

range and large local stockholdings 

through their Sydney and Melbourne 

sales offices as well as independent 

Australia wide distributor networks. It 

is renowned for high performance and 

energy efficient AC and DC motors and 

variable speed drives, industry leading 

servo products and digital positioning 

systems, along with specialist products 

such as stainless steel motors and washdown 

drives, stand-by generators and 

light towers. 

Baldor Australia Pty Ltd 

02 9674 5455 

marketing.au@baldor.com 

www.baldor.com.au 

Features 

• Increased efficiency and power factor performance 

• Operates at optimal system efficiency point with variable speed control 

• Increased system reliability with fewer mechanical parts 

• Simplified installation or retrofit with gearbox foot print 

• Inpro/Seal® combination slinger and labyrinth non-contact shaft seal protects 

motor from water ingress and contamination 

• Easy to use drive control parameters 

• Interfaces easily to building automation control systems 

• Replaces high maintenance conventional gear and belt drive arrangements 

• Quieter operation than conventional motor/gearbox system 


85


Latest AKD servo 

system solutions 

ollmorgen is an established 

name in the 

field of industrial motion, 

which with the release 

of the latest Advanced 

Kollmorgen Drive AKD, 

brings leading edge performance 

supported by the 

full range rotory, direct 

drive, and linear motors, 

actuators and gearheads 

distributed by Motion 

Technologies. 

New for the AKD series is the move to Ethernet 

coms, supporting Ethercat, Synqnet, Modbus/TCP and 

Canopen as standard on all drives. With their compact 

size, the feature-rich AKD drives provide a solution 

for nearly any application. The AKD range spans from 

3amp through to 96amp, with drives for single phase, 

three phase and high voltages. A modern servo system 

should be easily tuneable, so the AKD runs standard 

with auto, wizard and manual tuning. All major feedback 

types are included in the standard drive, including 

Endat, Sine encoder, incremental encoder, resolver, 

Hiperface, BISS and SFD. 

Kollmorgen matches the AKD to the AKM motor 

series, with five frame sizes and compact construction 

to offer predetermined performance and efficiency. Also 

produced in the USA and shipped from the same facility 

as the drives, AKM motors give the Kollmorgen AKD/ 

AKM combination true plug-and-play performance, 

convenience and ease of implementation. 

Should a gearhead be required to achieve the best 

motion solution, Kollmorgen links with partner Micron 

for the complete range of planetary reducers, in in-line 

or right-angle orientation. Microns gearheads are market 

leaders, with models with standard or precision 

construction, as well as the Gearhead Express lines 

which offer 24-hour turnaround with mounting ready 

for the AKM motors. 

Motion Technologies Pty Ltd - 02 95244782 

www.motiontech.com.au 

New Demag rotar 

emag Cranes & Components has further expanded 

their range with the introduction of the ZBE/ZNE 

cylindrical-rotor motor. Demag has added a drive to its 

product range that meets the requirements of efficiency 

class IE2 (High Efficiency), which applies all over the 

world. 

Simultaneously improving cost and 

environmental impact 

With effect from 16 June 2011, the EuP Directive (EuP = 

Energy using Products) specifies that only low-voltage AC 

motors with an output of between 0.75 and 375Kw may be 

placed on the market if they correspond at least to efficiency 

class IE2 (IE = International Efficiency) when covered by 

the Directive. This rule is based on targets agreed to protect 

the climate and to cut CO 2 emissions. 

New Demag motors meet the requirements of the new 

international standard defined in IEC 60034-30:2008. 

These energy-saving motors make it possible to save 

costs and, at the same time, to reduce the burden on the 

environment. Units are designed to be used as drives for 

duty factors of up to 100% at ambient temperatures of up 

to 40 deg. Celsius and at altitudes of up to 1000m above 

sea level. They are suitable for operation in continuous 

roller conveyors for uninterrupted materials handling as 

well as for long-term applications, such as for driving 

pumps, fans or compressors. 

The motors can be connected direct to mains supply or 

operated with frequency inverters. 



motor goes green 

Thanks to their efficiency, which is up to 5% higher, 

the new Demag motors require less primary energy for 

the same mechanical shaft output in nominal operation. 

Consequently the operating costs are also reduced, which 

results in a higher return on investment. 

About Demag Australia 

Established in Australia in 1962, Demag Cranes and Components 

are a multi-national specialist designer, manufacturer, 

supplier & installer of cranes and crane components. 

Head Office is located in Smithfield, NSW, with branches 

in all states and a complete distributor network. Demag 

Cranes and Components can provide effective solutions 

to material handling problems through a comprehensive 

range of standard and custom designed lifting equipment. 

Full product support is offered by Demag with technical 

product representation and a 24-hour, 7 day a week 

breakdown, repair and replacement parts service at every 

state branch. 

Demag remains the global market leader in overhead 

travelling cranes, electric chain and wire rope hoists, wheels 

and drives with solutions for all applications. 

Demag Cranes & Component - 1300 336 241 

011042_RoaringSuccess_SYC:Layout 2 2/3/11 9:03 AM Page 

sales@demag.com.au 

Growth 

Factor 

Some companies have it 

running through their veins. 

Others require a transfusion. 

your business 

+ our expertise 

= roaring success 

www.roaringsuccess.com.au 

P: 03 9694 4408 

Cost-efficient 

mounting options with 

alignment-free drives 

he new HD AFD configuration, which cost-effectively 

integrates motor and gearbox, joins Bonfiglioli’s 

expanding range of Australasian-engineered 

mounting options. It offers an alternative to laser-aligned 

baseplate types that allow the use of close coupled IEC 

B5 flange mounted motors up to a G315 frame size. 

The HD AFD combinations – with capacities up to 

1722kW and 150,000 Nm – complement Bonfiglioli’s 

Hi Torque drives and offer quick, trouble-free assembly 

and maintenance of high speed components including 

fans, fluid couplings and brakes. 

“The 58,000Mm HDO 130 shown is one of a broad 

range of HD AFD models that can save both time and 

money in a range of applications because there is no 

need to laser-align the motor and gearbox shafts,” says 

the Managing Director, Bonfiglioli Transmission (Australia) 

Pty Ltd, Mr Malcolm Lewis. 

In addition to reduced initial costs compared with 

traditional baseplate designs, the HD AFD configuration 

enhances serviceability by permitting high speed 

components to be removed and replaced without the 

need for re-alignment. Applications include conveyor 

drives, shuttle drives, bucket elevators, inching drives 

and other materials handling equipment. 

The HD AFD is produced in Australia on Bonfiglioli’s 

new production and testing line that cuts delivery times 

out of Europe by more than half for most models. Local 

production, combined with in-depth local engineering 

expertise, enables Bonfiglioli to custom-engineer specific 

solutions for industrial equipment and mobile equipment. 

“The HD series is ideally complemented by the 

Trasmital 300 series planetaries, which are compact, 

and yet extremely torque dense,” says Lewis. 

Trasmital drives can be specified and assembled in 

Australasia and planetary gearbox combinations are 

available here with peak torque outputs of more than 

1.195 million Nm. Even larger Trasmitals are under 

development for ultra heavy duty applications, particularly 

in resource industries. Applications range from 

cranes and winches, conveyors and feeders, mixers, 

agitators, and aerators, clarifiers and thickeners. 

Give new life 

to your business 

Bonfiglioli Transmission (Aust) - 02 8811 8000 

malcolmlewis@bonfiglioli.com.au 


87


High-performance drives for 

port facilities 

Cranes in shipyards, container terminals and other port facilities require highly reliable, powerful drive mechanics and electronics 

acing a ceaseless stream of multi-ton loads, drives in 

portside gantry cranes are under constant pressure to 

perform. Users need and demand reliable solutions that 

deliver excellent dynamics, positioning precision, and cost 

efficiency in equal measure. Hoist and trolley drives used 

in shipyard or container terminal cranes therefore require 

specialised mechanics and electronics suitable for this 

demanding application area. 

Cranes perform a simple job: they pick up a load at a 

specific position, and put it down again at another. In order to 

reliably accomplish and ensure a sufficient level of precision 

during this operation, they do depend on drives that are ideally 

adapted to this task. "Cranes are equipped with geared 

motors featuring integrated brakes. These are combined with 

frequency inverters for centralised acceleration and speed 

profile control," explains Nord Drivesystems. Since port 

cranes handle extremely large loads, their geared motors are 

designed to withstand high radial and axial forces. They also 

provide a range of key functions: enable a soft start with a 

high starting torque, ensure virtually shock-free motions, 

facilitate the synchronisation of several drives, provide a 

powerful hoist function, and allow for efficient generative 

braking via parameterisable ramps. “After a manufacturer 

has decided on a pre-selection of drives for the overhead 

crane and trolleys, we as a drive supplier will suggest suitable 

drive ratings according to customer specifications.” 

Geared motors under extreme loads 

For this purpose, Nord can specify and deliver helical shaft 

geared motors and frequency inverters, all from in-house 

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production. The geared motors for cranes and trolleys cover 

performance ranges up to 160kW with a wide choice of gear 

ratios. Available as two- or three-stage designs with a hollow 

or solid shaft, users can choose between models with a 

foot mount, flange models and shaft-mounted models. All 

types are equipped with the same space-saving housing 

which allows for easy integration. Motors used in cranes 

and trolleys often operate around the clock in very busy 

ports. However, if the turnover decreases due to market 

conditions, some loading facilities may stand still for long 

periods of time. The build standard of the drives must, of 

course, ensure that normal operation can be directly even 

after such prolonged standstill. In addition to these changing 

load factors, recurring harsh climatic conditions and 

extreme temperatures as well as the salt water in maritime 

environments, all call for suitable long-term corrosion-proof 

material. If required, gear units from Nord are available 

with IP55 or IP66 protection. Moreover, all models are also 

available as ATEX versions. 

User-friendly drive electronics 

Frequency inverters from NORD's SK 500E line are an ideal 

match for geared motors used in cranes. The robust, highperformance 

units provide an efficiency of more than 95% and 

a typical overload capacity of 200% for 5s. Compatible with 

all standard bus interfaces, the units are easy to operate and 

program. Basic models feature an integrated brake chopper 

with management for brake motor control, which is ideally 

suited for use in hoist applications. The inverters operate 

with sensor-less current vector control. Alternatively, speed 

feedback can be used in applications with elevated requirements 

for speed control precision and overload capacity. The 

Posicon extension enables these inverters to perform intelligent 

position control tasks, rendering additional modules 

for such functions in higher-level controllers unnecessary. 

The cost-efficient ‘safe stop’ feature according to EN 954-1 

and EN 13849-1 is optionally available. 

Tried-and-tested combinations 

NORD's drive solutions, which are installed in a wide range 

of crane facilities with different capacities, have proven 

their reliability for years. One example is the transtainer 

crane at the Scandinavia quay in Travemünde, Germany. 

With more and more cargo runs in the Baltic Sea, boosted 

by the eastern expansion of the EU, the port authorities 

have considerably extended the Scandinavia quay in the 

last few years. Now the largest part of the port, the facility 

comprises cranes with a load capacity of 56t which act as 

hubs for all kinds of goods that arrive on trucks, in containers 

or in swap bodies and must be transferred. In total, 60 

NORD drives are used in this application. 

The installation of the world's biggest shipyard portal 

crane, ‘Goliath’, in Odense, Denmark, was a considerably 

larger enterprise still. For this application, Nord developed 

a drive concept with a sophisticated control system and a 

total of 68 helical bevel geared motors. The drives for the 

shipyard crane, which master a maximum load of 100 t, 

ensure precise directional stability. Controlled DC drives 

in the crane hoist and inverter-controlled three-phase asynchronous 

motors in all trolleys ensure stageless and smooth 

The SK 500E line of frequency inverters is available in six sizes 

speed control. Combined with continuous brake monitoring 

through micro switches, this ensures high positioning precision 

and plant safety. 

Getriebebau NORD GmbH & Co. KG 

www.nord.com 

Ready made or Custom made 

www.ronsongears.com.au 

Visit us at National Manufacturing 

Week 2011, 24-27 May 2011, 

Stand 2020 in the Engineering Zone 

exclusive distributors for KHK 


89

CNC Controllers 

Stay in control 

Today's 'Open' CNC controllers are more than just fast computers; they are the front line 

interface that allows you to generate very complex multi-axis machining strategies relatively 

easily. Further, they offer tool-offsets at a push of a button, allow servomotors to be tuned on 

the fly, and automatically handle the replacement of broken tools. They provide control over 

processes, for example, activating coolant chillers and communicate with temperature sensors 

and/or linear feedback scales to allow positional errors to be determined and corrected. 

B y M a r t i n O a k h a m 

e’ve all seen the phenomenal developments in computing 

over the last decade – the number crunching 

capability is nothing short of staggering. It’s this technology 

that the CNC controller manufacturers have capitalised on 

when offering precision multi-axis control of today’s machine 

tools. In fact, CNC controls only differ from PCs in that they 

are Input/Output (I/O) orientated, spending the majority of 

their processing power conditioning control signals, driving 

servo motors, and monitoring the kinematics of the machinery 

being controlled in order to make ‘real time’ adjustments to 

improve surface speeds and toolpath accuracy. 

5-axis control 

A question frequently asked is: would there be productivity 

gains by investing in 5-axis machines and their associated 

multi axis controls to replace 3+2 setups ‘Customers are 

often discouraged from purchasing 5-axis machines by 

the high cost associated with this technology. However, 

opting for 5-axis machines can significantly reduce production 

costs. They are extremely flexible - being capable 

of machining around five sides of a cube in a single setup. 

They can also be used in a basic 3-axis mode if necessary, 

reducing the number of machines and operators required. 

The negatives regarding 5-axis machines is that generally 

they are less stiff, thus smaller high-speed cuts have to be 

made. This puts huge demands on the controller, which has 

Siemens 840D is its flagship controller used extensively in the 

aerospace sector due to its high speed multi-axis capability 

and technical advantages. These include its Volumetric 

Compensation System (VCS) mandated by the need to fabricate 

large aircraft parts. 

Siemens 828D controller offers job shops an affordable CNC 

with an improved graphical interface, online animated help and 

connectivity features. 

to cope with large quantities of data and huge acceleration/ 

deceleration velocities by using ‘look ahead’ functions that 

work in much the same way as a racing driver pre-empting 

the best path to take and where to brake. 

Firstly, the driver’s knowledge of the racetrack is important. 

He/she has to know when a sharp curve is coming in 

order to slow down just enough to take it safely. CNC lookahead 

performs a similar role, giving the CNC advanced 

knowledge of the sharp curves coming up. Similarly, how 

quickly the driver reacts to what other drivers do, and other 

unpredictable effects, can be compared to the CNC's servo 

loop times -including position loop, velocity and current loop. 

Also consider the smoothness of the driver’s execution as he 

goes around the track. Skilfull braking and accelerating have 

a significant impact on performance. Programmed bell-type 

acceleration/deceleration curves give a similar smoothness 

to machine tool acceleration. Look-ahead also helps here, 

because it allows many small acceleration/deceleration 

adjustments to replace an abrupt directional change. The 

number of look-ahead blocks can range from two blocks to 

hundreds of blocks depending on the controller. The number 

of blocks required depends on factors such as the minimum 



Right: The new Fanuc 30i/31i/32i 

Model B (or 3xi-B for short) series 

offer outstanding features, 

including a large number of axes 

and multichannel capability. 

Left: The Fagor 8070 CNC 

features High-Speed algorithms 

developed for high speed 

machining application, ensuring 

a smooth contoured finish. It 

also makes operations such as 

turn-and-bore, extremely simple 

to set up and execute. 

part program execution time 

and the acceleration/deceleration 

time constant, but 

15 blocks of look ahead is 

probably the minimum acceptable 

value. A ‘dwell’ as an 

axis waited for data to arrive, or for a rotary 

axis to reposition, would result in a poor surface finish just 

as it would on any manual 3-axis machine. 

Of course, there are many jobs that can only be cut economically 

using continuous 5-axis motion. These include 

more complex contoured parts such as mould cavities, blisks, 

impellers, and other turbine-type parts where tool orientation 

must be controlled in order to reach a surface to be machined 

without requiring extended tools that are likely to chatter. 

Ball-nose end mill compensation in continuous 5-axis 

applications requires everything the current technology has 

to offer. In order to properly compensate for a ball-nose end 

mill as the part or the tool pivots, the CNC must be able to 

dynamically adjust the cutter compensation vector in X, 

Y and Z simultaneously in order to keep the tool’s contact 

point at a constant. This is because when rotary axes pivot 

the tool, the tool length offset that normally affects only the 

Z-axis now has components in X, Y and Z. In addition, tool 

diameter offsets that normally only affect the X and Y-axes 

also have X, Y and Z components. As the tool may be feeding 

in the rotary axes while it’s cutting, all of these offsets 

have to be updated dynamically to account for continuous 

changes in the tool’s orientation. 

Tool load compensation 

Another example of adaptive control is 'tool load compensation', 

this feature automatically changes the feed rates based on 

spindle load parameters set by the operator. Instead of setting 

a safe feed rate based on average tool load conditions, so the 

tool doesn't break, feed rates are set for the maximum tool 

load condition and the control automatically reduces the feed 

rate based on the actual tool load conditions while the part 

is being cut. This technique is proving to reduce cycle times 

by up to 30% on average; however its efficiency is dependent 

on the original program. A well-programmed component 

will already be using optimised feeds and speeds. A feed 

rate limit can also be used as a cue to determine when a tool 

has reached the end of its life. For example, when the tool 

becomes so dull that the feed rate reaches 80% of normal, 

the CNC will either enter a hold condition that allows the 

operator to change the tool or automatically changes it if it 

has access to sister tooling. 

Many of today's CNC systems can integrate 

off-the-shelf applications such as vision 

systems seamlessly within the control solution, 

thus providing more value. Software is 

also helping manufacturers to standardise 

hardware for different machining processes, 

resulting in reduced inventory and 

maintenance costs on the floor. For example, 

Siemens Automation and Drives ' Sinumerik 

840D control software architecture provides 

the manufacturer a single hardware platform 

to do milling, turning, grinding, laser cutting, 

tube bending, friction stir welding, etc., with 

all of the capabilities unified under a single 

software pool within the control architecture. 

Open architectures 

More recently, CNC developers have been focusing 

on the ability to connect to the internet and 

‘open’ architectures generally. More and more 

machine shops will use this capability to access 

tool databases, customer databases, SPC packages, 

remote diagnostics etc, however, the chief advantage is 

that they permit continually enhanced functionality through 

software upgrades, just like any PC today. Open CNC solutions 

allow CNC machine tool users to deploy a unified 

automation strategy, which depends on all the computer 

systems from engineering design centres to factory-floor 

machine tools to communicate seamlessly. 

MTConnect 

MTConnect for example makes it possible for machine tools 

and other manufacturing equipment to share information—a 

lot like the way people do with Twitter, Facebook, LinkedIn 

and other internet-based social networking tools. 

Just as Twitter is one way to share a brief but important 

idea with a network of friends, MTConnect enables machine 

tools to share critical data so that other devices and shop 

personnel can respond appropriately. The data being shared 

could include alarm messages, part counts, inspection results 

and similar ‘vitals’ about the machine and its performance. 

So does it really matter what make of CNC is fitted (or 

retrofitted) to machine tools Well, yes and no, depending 

on the type of machine tool and work it is to undertake. OEM 

machine tool builders work with the majority of controller 

manufacturers, who in turn work with CAM developers to 

ensure the best is obtained from all parties. The machine 

vendor will advise on suitable controllers from a technical 

point of view, and may even help on the software side. Each 

make of controller has its own strengths and weaknesses, 

which the customer must take into consideration when making 

a purchasing decision. These include the number of axes possible, 

positional accuracy obtainable on the given machine 

tool, maintenance costs, long-term support, and post-processor 

accuracy - all of which are very application-specific. 


91


New CNC gear and software spur 

shop-floor productivity 

Shop efficiencies start with the machine tool controller, as today’s CNC equipment offers 

machine operators myriad tools for improving part surface finishes, allocating machine time, 

and cutting job cycle times. With the latest CNC gear, manufacturers typically get a much 

easier-to-use controller packed with built-in software, allowing machinists to handle many 

programming tasks right at the control. 

B y P a t r i c k W a u r z y n i a k 

n affordable midrange control, 

the Siemens Sinumerik 828D 

CNC released last year is aimed at 

job shops seeking a cost-effective but 

feature-rich machine controller that 

uses the Linux operating system, new 

applications software, and the ability 

to receive and send text messaging to 

view a machine tool’s status and alter its 

functions with return messages. “One 

of the biggest hooks is that the software 

version on the 828D is the same that’ll 

be on the 840D—it’s the same lookand-feel 

across the line,” notes Randy 

Pearson, manager, dealer and end-user 

support, Siemens Industry Inc. IL 

The Siemens 828D also features an 

updated HMI, called Sinumerik Operate, 

that combines Siemens’ previous 

HMI Advanced and ShopMill/Shop- 

Turn HMIs that incorporate help functionality 

on every screen. With its new 

Animated Elements help capability, 

machine operators can easily navigate 

through complex jobs with the builtin 

simulations. “You go to the screen, 

a little animation pops up and shows 

you how it works,” Pearson adds. “In 

the past, what we had was more static. 

This way it shows how a drill moves, 

or how a tool does a conventional cut, 

with the animations.” 

The 828D is a panel-based NC unit 

that contains no battery, fan, hard 

disk, or any moving parts, Pearson 

adds. The company’s choice of an embedded 

Linux open-source operating 

system helps minimise the requirements 

associated with Windows-based 

machines and improves protection 

from malicious viruses that target the 

Windows operating system while the 

Siemens i sinumerik 828D is aimed at production-type three and four-axis machining. 

machine is connected to a plant-wide 

network, he adds. “It’s stable, and if 

you put it on a network, nobody’s bothered 

to write viruses for it,” Pearson 

observes. “It’s stable, it’s simple, and 

it boots fast.” 

Aimed at production-type three and 

four-axis machining, the 828D is less 

expensive than the company’s flagship 

Sinumerik 840D control, which handles 

more high-end, complex machining 

chores such as five-axis aerospace, 

medical, or automotive applications. 

“We’ve positioned the 828 as a compact 

control that is really geared in 

terms of functionality and price to 

be in the midrange area,” notes Jon 

Cruthers, Manager, Business Development, 

Siemens Industry Inc., “whereas 

the 840 has a lot built-in, and there are 

not a lot of options. The feedback that 

we get from machine tool builders is 

that it’s priced aggressively.” 

Advanced connectivity functions 

on the new control include Siemens’ 

Easy Message system, which offers 

simple production status monitoring 

by text messaging. Depending 

on a user’s profile, the machine can 

transmit information about workpiece 

machining status, report on the tools 

in use, and send machine maintenance 

bulletins to mobile phones at any time. 

“One of the really neat technologies 

is the Easy Message feature,” adds 

Pearson, noting setup of the system 

is quick. “People are asking for this 

all the time. It kicks out a message 

and you send a response back to the 

machine.” Many users operate the 



system follows the path as fast and accurately 

as possible,” Webster explains. 

“Following the programmed path is 

only part of the requirement for large 

five-axis machining—error compensation 

is also a large factor in these types 

of machines. “Fanuc has addressed this 

concern with the release of 3-D rotary 

error compensation. This volumetric 

compensation feature allows for fiveaxis 

or error compensation within the 

entire machine envelope.” 

The recent release of interactive 

force compensation software dynamically 

corrects for the interaction seen in 

high-speed five-axis machines caused 

by the rapid acceleration changes of the 

linear and rotary axes, Webster adds. 

“This interaction reduces accuracy at 

the tool tip but cannot be corrected 

in the program without lowering feedrates.” 

Software enhancements help Fanuc 

controls used in everything from job 

shops to aerospace applications. “We 

produce CNC controls that are used by 

all sectors of manufacturing,” Webster 

says. “The latest 0i-D has all the fea- 

High-Speed algorithms in Fagor’s 8070 

CNC optimises machining with faster 

cutting speeds and smoother contours. 

system using prepaid mobile phone 

GSM cards that simply plug into the 

machine. 

CNC evolution lately has focused 

around improving the productivity of 

individual machines and integrating 

the machines into the overall factory 

system, notes Paul Webster, Manager, 

Product Engineering for Fanuc CNC 

America Corp. “The recent economic 

climate has highlighted the need to 

increase productivity without capital 

expenses or labour increases. This 

means getting more out of each machine, 

and automating the machining 

process,” Webster states. “Controlsystem 

development has followed this 

approach. To assist machine operators, 

maintenance personnel, and supervisors, 

we are seeing improvements in 

machine operability, reliability, and 

connectivity.” 

The most recent control from Fanuc 

is the new FS0i-D line, which was 

released last year and is designed to 

be price-competitive with many alternative 

solutions. “The 0i-D is a nano 

[nanometer] CNC that shares many of 

the features with the top-of-the-line 30i 

series of CNCs,” Webster says. 

For five-axis machining, Fanuc has 

made several significant advancements, 

he adds. “Improvements to smoothing 

functions—Nano-smoothing 2, and 

Smooth TCP 2 make sure the control 


93


tures required for most applications and 

shares much with the top-performing 

30i, but at a much lower cost. Job shops 

can take advantage of the improved 

operability of the 0i-D or the high-end 

3xi family, such as Manual Guidance, 

off-line CNC machine simulation, and 

more PC-like operation.” 

The advancements made in five-axis 

error compensation and accuracy were 

specifically designed to meet the needs 

of the aerospace market, he adds. In 

addition, aerospace applications use 

high speed, high-powered spindles that 

Webster notes were developed with the 

needs of titanium and other more exotic 

materials in mind. 

Heidenhain has added Kinematics 

Comp for machine tool builders, which 

allows incorporating new compensation 

tools into machines using the Heidenhain 

iTNC 530 contouring control. 

“When you commission a machine tool, in our control 

system, you detail every moving element of the machine 

and how they all relate to each other,” notes Chris Weber 

of Heidenhain. “You can imagine on a five-axis machine, 

if I’ve got a tilt-swivel head, the possibilities in five-axis 

motion Project3:Layout are pretty high 3 15/4/10 to hit something 2:38 PM you Page don’t 1 want to 

Cutting a complex 5-axis job under the control of a Fanuc FS0i-D line 

hit. Also as machines wear, and as machines warm up, those 

relationships change due to thermal expansion typically. 

“Kinematics Opt allows you to go in on a machine and 

at fixed intervals, even between parts, go in and reset those 

values,” Weber says. “As things start to drift a little bit, I 

can go in and re-comp based on the current machine status. 

It involves using a calibrated sphere on a table of the 

machine. The enhanced Kinematics Comp software offers 

machine builders new tools for compensation during initial 

machine setups,” he adds. 

The Dynamic Distribution of Machining Operations 

(DINDIST) feature of the Fagor 8070 CNC makes it possible 

to distribute the machining operations among the 

execution channels on multi-spindle lathes. “Just program 

the machining operations for a single turret, then once the 

DINDIST function is activated, the machining operations 

are automatically distributed among the turrets without extra 

calculations, making it possible to optimise and minimise 

machining time considerably,” says Todd Drane of Fagor 

Automation Corp, IL. “This feature makes turn-and-bore 

operations that are so common on multi-turret machines 

extremely simple to set up and execute. 

Energy-saving features have been a focus for control 

systems development at Bosch Rexroth, notes Karl Rapp, 

Automation and Machine Tool Branch Manager, Bosch 

Rexroth Corp.—Electric Drives and Controls USA. “Starting 

with IndraMotion MTX ega for the CNC, Bosch Rexroth 

is now offering PLC logic and library functions combined 

with HMI screens so the OEM/user can implement measurable 

energy monitoring into the control system,” Rapp says. 

“All data can be accessed via OPC and Ethernet TCP/IP for 

centralised collection in a facility. Bosch Rexroth Germany 

has several systems running to gather real-world data 

and measure the benefits. 

2010 Copyright by Society of Manufacturing Engineers. All 

rights retained. This article appears with permission from 

Manufacturing Engineering, the official publication of the 

Society of Manufacturing Engineers (SME) 


Perfectly tailored 

Siemens launches new CNC and drive system for the compact class 


ith the Sinumerik 828D Basic T and the Sinamics 

S120 Combi, Siemens Drive Technologies Division is 

perfectly rounding off its product range for the CNC compact 

class. What's more, Siemens is now offering an entry 

level CNC for the compact class, which has been designed 

in line with standard turning machines with a high level 

of performance, precision and availability. Together with 

the new Sinamics S120 Combi multi-axis drive module it is 

ideally suited to this machine class. It is here where power, 

precision and robustness play a decisive role. 

With the Sinumerik 828D Basic T, Siemens has developed 

a robust and precise CNC for worldwide use. With 

the Sinumerik 828D Basic T, Siemens is combining a high 

degree of quality and reliability at a reasonable price. As an 

entry level CNC for the compact class, it is ideally suited 

to standardised turning machines with up to five axes/ 

spindles, including driven tools. Equipped with a screen, 

keyboard and CNC electronics, each unit merely requires 

a few interfaces and cabling, thereby maximizing system 

availability. In addition, the existing operator panel, which 

consists of die-cast magnesium, enables the new Siemens 

CNC to function particularly reliable even in harsh operating 

conditions. Parts that are subject to wear such as fans, 

hard disks and batteries are now a thing of the past. This 

enables maintenance-free operation. 

Hi-tech for the compact class 

Modern processor technology and software architecture are 

based on 80-bit NANOFPprecision (80-bit floating-point 

precision). Using this technology, precision values in the 

region of one tenth of a micrometer (μm) can be achieved. 

The degree of precision which can be achieved in practice 

is therefore not limited by the control, but is instead defined 

by the capabilities of the mechanical components. 

In addition to the high degree of precision, the Sinumerik 

828D Basic T also facilitates particularly flexible use, as 

it is able to execute drilling and milling operations in addition 

to a variety of turning operations. With intelligent 

kinematic transformation between the spindle and X axis, 

the most diverse range of milling and drilling processes 

can be executed on the front face and peripheral surface of 

the workpiece. Thanks to Sinumerik Operate, Sinumerik 

828D Basic T has been able to integrate a user-friendly CNC 

user interface with programming and setup procedures in 

a reliable and intuitive manner. 

A special function of this system is the Easy Message 

function, which updates responsible staff members on all the 

essential manufacturing process data via SMS. If a machine 

requires some new raw parts or a turning tool is approaching 

the end of its service life, the Sinumerik 828D Basic T 

sends corresponding details via SMS, thereby maximising 

the productivity of the machine. 

Sinamics drive - robust, yet easy to maintain 

To round off the new CNC, Siemens offers the new Sinamics 

S120 Combi, an integral drive system, which similarly to the 

With the Sinumerik 828D Basic T and the Sinamics S120 Combi, 

Siemens Drive Technologies Division is perfectly rounding off its 

product range for the CNC compact class. 

CNC, is perfectly tailored to the requirements of compact 

standard machines. In terms of the Combi drive, robustness 

is regarded as one of its key features. To ensure this high 

degree of robustness, the infeed unit as well as the three 

to four Motor Modules, among other components, have 

been integrated into a single unit. This therefore reduces 

the number of wiring interfaces required, while a heat sink 

allows heat to be optimally dissipated from the machine, 

even if one of the power units is under full load. 

If the machines are used in tropical ambient conditions, 

the drives will need to reliably withstand fluctuations in 

voltage and frequency in the grid as well as resist heat and 

moisture. This is exactly where the Sinamics S120 Combi 

comes into its own. 

The Sinumerik 828D Basic T has already been integrated 

into the SinuTrain training package for Sinumerik Operate. 

As such, knowledge of operating a turning machine with 

the new control can now be acquired and deepened. What's 

more, SinuTrain is also ideally suited to offline programming. 

Here you will have everything at your fingertips, as 

if it was the actual machine-based CNC, such as the wellestablished 

programming methods including Sinumerik 

CNC programming language, ISO code programming and 

ShopTurn machining step programming. 

With this version, Siemens Drive Technologies Division 

has extended its range of controls in the Sinumerik 828D 

compact class. An extensive range of machine tool controls 

is now available for each and every CNC requirement, from 

Sinumerik 828D for demanding turning and milling machines 

in the workshop, to the Sinumerik 840D sl for premium 

applications and the Sinumerik 802 series for standard 

machine applications. 

Siemens Ltd. Australia - 03 131 773 

industry.sales.au@siemens.com 

www.siemens.com 


95


Fanuc - The latest generation 

of CNC controllers 

The new Fanuc CNC controllers of the Series 30i/31i/32i Model B (or 3xi-B for short) are ideal for 

sophisticated and complex machine tools. Their outstanding features include a large number of 

axes and multichannel capability. 

ompared to previous models, the new B Series feature 

significant advancements, numerous detail improvements 

and additional functions for punch presses and laser 

cutting machines. FANUC has also introduced a new member 

to the FANUC controller family: the CNC 35i-B Series 

based on the technology of the 30i-B Series and developed 

primarily for transfer line and handling applications. 

A bus system for servo and spindle data 

The servo system for the new generation of controllers 

and drives brings major improvements. A new high-speed 

servo-processor increases the basic output of the digital 

axis drive, enabling a much higher number of axes to be 

activated without the need for an additional board. Data is 

transferred via the new Fanuc Serial Servo Bus FSSB and 

the corresponding optical cable. 

The new FSSB is even faster and offers a decisive 

advantage: it now transfers spindle data also. Servo and 

spindle amplifiers are connected to the CNC control by a 

single optical cable. The reduced wiring complexity saves 

time and cuts costs while eliminating potential sources of 

fault, which is in keeping with Fanuc’s goal of maximising 

system availability. The advantage of optical data transfer 

over electrical cable transfer is that it greatly minimises 

the system’s susceptibility to faults. 

Other improvements in the servo system are new Alpha i 

servo amplifiers which use low-loss power devices designed 

to help save energy. The new pulse coder backup unit has a 

rechargeable battery and charging circuit which eliminates 

the need for battery replacement. 

A fault current detector integrated in the servo amplifier 

is an innovation that allows preventive maintenance. A 

diagnostic screen indicates the servo status when an alarm is 

activated. The amplifier’s integrated self-test function with 

operator guidance via the CNC screen enables mfaults to be 

localised easily and cleared more quickly. A new multiple 

detector evaluation unit provides additional support. 

PMC triples the speed 

The integrated programmable controller – which FANUC 

calls “PMC” – has been upgraded for higher performance. 

The high-speed PMC of Model B controllers is three times 

as fast as in the previous controller, and program memory 

has tripled. 

A multichannel PMC is available for complex machining 

tasks which entail a high degree of automation. It allows 

up to five independent PMC programs to be run simultaneously 

at maximum speed. This means there is no need for 

an additional external programmable controller. 

The previous I/O Link has found a high-performance successor 

in the I/O Link i. The new link can transmit twice as 

many PMC DI/DO signals per channel and allows 24 groups 

to be connected as compared to the previous 16. This also 

benefits the integrated Dual Check Safety function because 

a single I/O Link i cable is all that is needed to transfer the 

secure signals. No additional channel is required. 



Use of the I/O Link i also opens 

up new diagnostic options. A so 

called precision fault detector allows 

the user to determine whether 

a digital output is not functioning 

properly or is disconnected. The 

source of fault is then displayed on 

the CNC screen, thus significantly 

reducing diagnostic times. 

Broader range of 

uses, numerous detail 

improvements 

FANUC has developed new functions 

for the new CNC controllers 

of the Series 3xi Model B which are 

suitable for use on punch presses 

and laser cutting machines. The 

large motors and amplifiers support 

up to four units without the need 

for an interposed module. 

With large machine tools, it is 

often the case that multiple operating units are needed at 

any one time. Fanuc can now offer cable lengths of up to 100 

metres between the CNC controller and a second standard 

LCD using an Ethernet connection. Display signals can be 

transmitted over a length of up to 50 metres between two 

LCDs. 

The Model B controllers come with numerous software 

developments offering new CNC functions. To 

reduce machining times, it is for example possible to 

corner-round high-speed transitions without having to 

reduce the feedrate to zero at the end of a block. This 

pays dividends, particularly when running part and mould 

making programs which contain numerous positioning 

commands. Other new features include functions for 

simple thread finishing and thread cutting; rotational 

speed is freely selectable and can be adjusted during the 

cutting operation. 

Fanuc attaches special importance 

to simple and straightforward operation 

of the CNC controller. This is why 

the new models have an improved program 

management system with new 

administration and display functions. 

User-friendly changes have also 

been made to MANUAL GUIDE 

i, Fanuc’s workshop-oriented programming 

software.For example, the 

simulation window is now twice as 

large, allowing enhanced display of 

cutting simulations. The operator has 

the option of switching to alternative 

double windows for multichannel applications. 

Other detail improvements include 

a simultaneous string search function 

which can be used to search multiple 

channels simultaneously when running 

multichannel routines. 

Simple data communication 

Another user-friendly feature is a USB port which allows the 

use of USB storage media for data input and output. A USB 

stick can be used for transferring data instead of the customary 

Compact Flash card, thus freeing up the CF card for use 

as an additional non-volatile program memory for the CNC. 

The network functions have also been improved. In addition 

to the conventional Ethernet On board, the transfer speed 

of which has been optimised, there is a network port which is 

integrated on the main board. This option is available for ultraflat 

Fanuc CNC controls (LCD CNC) and eliminates the need 

for an additional option slot. The additional port, which supports 

FL-Net and Fast Ethernet, has a separate CPU which 

facilitates stable Ethernet communication in real time. 

CNC Parts for Australia - 02 9700 1555 

www.cnc-drives-controls.com.au 

3D Scanning Software! - Geomagic 

• 3D Scan data processing Software sales and support. 

• WE ARE INDEPENDENT OF HARDWARE! 

• Geomagic is the easiest to use and the most powerful suite of 

point cloud processing software available in the world. 

• Cimcore, Faro, Handyscan, Kreon, Baces, Z scanner, Nikon, 

Vivid, GOM, Leica, Surphaser, and many others. If it generates 

points Geomagic can work with it. 

• Come and chat at Stand 773 Austech. 

• 11 Years Experience Using and Supporting Geomagic. 

P: 02 9153 9974 geomagic@wysiwyg3d.com.au www.wysiwyg3d.com.au 


97

Compressors 

Two variable outputs doubles benefit 

With many industrial air compressors employing a form of variable speed drive technology, there is a 

need to find the next competitive edge. Sullair Australia has taken up the challenge with the design 

of a Variable Speed Drive (VSD) combined with a Variable Output Compressor (VOC) in one unit. 

Andrew Dove, Product Development Manager with Sullair Australia, outlines the benefits of the dual 

technologies incorporated in Sullair’s range of VOC/VSD air-compressors. 

ariable Output Control (VOC) technology has been 

employed for many years. It provides variable output 

compressed air in response to application demand – with a 

simple mechanical design. In essence, the airend volume 

is varied to match demand by increasing or decreasing the 

exposure of ‘vents’ in the airend floor by the rotation of a 

spiral valve underneath. While the spiral valve provides a 

robust, low maintenance form of variable output compression, 

the amount of achievable turndown using this method 

is limited to 50% of full load output. 

In many real world applications, variations in air demand 

are the rule rather than the exception. Variations of more 

than 50 % of maximum capacity can occur in production 

environments due to shift changes, weekdays versus weekends 

or variations in workload of a specific machine in a 

manufacturing process. Plant air delivery can be reduced 

beyond 50% by using multiple compressors and managing 

their on/off cycles to meet the demand. However this 

increases the complexity of the system and may add to 

service and maintenance. 

The VSD Champion advantage 

The continuing evolution of compressor technology has 

seen the introduction of the Variable Speed Drive (VSD) 

air compressor as an alternative to variable output capacity 

reduction. The speed of the motor is controlled in proportion 

to air demand – providing immediate and efficient response 

to changing loads, Graph 1 highlights the energy saving 

advantages of the Sullair Champion range of VSD compressors 

compared to conventional load / unload compressors. 

Graph 1: The variable speed drive adapts motor speed to changes 

in air demand. Compared to constant speed compressors the 

VSD can deliver significant power savings under variable load 

conditions. 

The Champion V-Series variable speed drive compressors 

utilise Optimal Flux Technology (OFT) to significantly 

improve motor efficiency and extend the range of turndown 

possible compared to that of a standard VSD unit. Optimal 

Flux Technology has been proven to give dynamic motordrive 

response to demand, thereby increasing optimum 

performance and efficiency. The resultant reduction in motor 

temperature removes the need for forced cooling and torque 

de-rating, extending the longevity of the motor. 

However, even the VSD design has its limits and if demand 

fluctuates beyond the turn-down limits of the VSD, 

power efficiency is compromised and it will not be possible to 

maintain the tight tolerances for the desired system pressure. 

Best of both worlds 

The solution that Sullair Australia has devised is a fusion 

of the two technologies. The concept is relatively simple: 

utilise the variable speed drive to turndown to approximately 

30% of full capacity and then add the further 50% 

turndown of the variable output spiral valve to achieve a 

total turndown to 15% of full load as shown in Graph 2. 

The VOC/VSD combination design allows both trimming 

systems to operate within their optimum design parameters 

and efficiency zones. The end result is the Champion VOC/ 

VSD compressor. 


Compressors 

The use of the spiral valve with VSD allows for greater 

trimming to improve the system’s ability to match demand. 

Under these trimmed conditions, the average power consumption 

of the VSD compressor shown in Graph 3(a) is 

approximately 31% of full load, compared to Graph 3(b) 

(VOC/VSD) which shows consumption at 23% of full load. 

Power consumption, degree of turn-down and the 

stability of air supply are just three considerations in 

the overall assessment of compressed-air requirements 

for industrial facilities. To fully examine all factors a 

complete air-audit is recommended to determine the 

most efficient and cost effective compressor solution. 

Air-audits often reduce facility air running costs by 

thousands of dollars per year. 

Graph 2: A standard load on/off compressor operates at 100% 

or zero % capacity only; the VOC can be turned down to typically 

50% of full load capacity; the VSD to typically 30%. The fusion 

of VSD and VOC technology allows for a total turndown to an 

impressive 15% of full load capacity. 

The VOC/VSD compressor combines the energy efficiency 

and responsiveness of the VSD design with the 

added turndown range of the VOC spiral valve. The 

result is near constant pressure regardless of demand. 

The compressor may be kept at its most efficient point, 

maximising the energy savings that are achievable with 

both forms of compression. 

Graph 3a: At high levels of turndown the VSD design alone 

cannot maintain tight tolerances on system pressure and power 

demand oscillates. 

Graph 3B: With the unique Champion VOC/VSD compressor 

much tighter tolerances on system pressure are achieved with 

significantly reduced, but constant, power consumption. 

Power consumption, degree of 

turn-down and the stability of air 

supply are just three considerations in 

the overall assessment of 

compressed-air requirements for 

industrial facilities. 

The new VOC/VSD compressors retain the key features 

of the individual VSD and VOC designs including 

IP54-rated electrical enclosure, dirty environment filters, 

deluxe monitoring and Optimal Flux Technology motors. 

To further enhance performance, Sullair Australia has 

added a thermostatically-controlled fan to the VOC/VSD 

compressor. The temperature is monitored and the cooling 

fan activated only when necessary to maintain temperatures 

at an optimum level, thereby reducing power consumption 

and noise further than continuous fan motor designs. 

The Champion VOC/VSD family of compressors ranges 

from 50kW to 185kW and is ideal for mid- to high-level 

industrial applications where variable air demand is common. 

All units are designed to withstand Australia’s harsh 

conditions with up to 50oC ambient temperature rating. 

Ambient operating temperature is an important selection 

criteria for air compressors in this country. Many compressors 

are installed in dedicated utility rooms where ambient 

temperatures can reach these extremes. The VOC/VSD 

range is backed by Sullair Australia’s extensive warranty 

plans and the AirSwap airend exchange program. 

For the end-user, the development of the Champion 

VOC/VSD air compressor delivers the best of both worlds 

- the energy efficiency and responsiveness of the variable 

speed drive coupled with the added turn-down of variable 

output control. The Champion VOC/VSD design is a better 

solution for varying air demand applications delivering 

greater energy efficiency, greater turndown, reduced 

maintenance costs and greater stability of delivered air 

pressure. 

Sullair Australia and Champion Compressors 

03 9703 9014 

mknowles@sullair.com.au 

www.sullair.com.au 


99

Compressors 

Sullair’s Champion V-Series variable 

speed drives 

ullair Australia’s, V-Series, range of compressors features 

‘Optimal Flux Technology’ to provide precise and 

dynamic calibration between drive and motor, to minimise 

losses and maximise performance and energy savings. 

The incorporation of Optimal Flux Technology 

in the V-Series has eliminated the need for forced 

ventilation and cooling and torque de-rating. Extensive 

testing of the drive and motor has shown that the 

temperature of the motor can be reduced by as much 

as 11° C, significantly reducing energy consumption 

on cooling and ventilation for the compressor. 

The MEPS-2 compliant motor incorporates spikeresistant 

wire to minimise the impact of voltage 

surges on start-up, thereby increasing the longevity 

of the motor. 

The variable speed capabilities of the drive and 

motor ensure that the motor is running at optimum 

capacity, regardless of the compressor demands. 

“A load on/load off compressor is more suited 

to applications where air demand is relatively 

constant. The Champion range of VSD compressors 

is the ideal compressor for varying load 

Learn more about the power 

of Verisurf by registering 

for webinars on our website, 

or call for an onsite demo. 

www.memko.com.au 

or 03 9013 5787 

Champion brand of VSD compressors from Sullair Australia 

maximises efficiency and energy savings. 

applications, such as where production shift changes or 

changes in use of equipment create demand highs and lows. 

VSD compressors are more efficient under these conditions 

and save users significantly on energy bills,” said Andrew 

Dove, Design Engineer with Sullair Australia. “The VSD 

is also the ideal partner to a load on/off compressor, where 

the on/off compressor meets the bulk of air demand and 

the VSD trims supply to meet the variations in demand 

more efficiently.” 

The Champion brand of V-Series compressors offers a 

range of operating specifications that are ideal for variable 

load conditions. The smallest unit, CSF18V delivering rates 

of up to 51 L/s, comprises an 18.5 kW motor with working 

pressures of between 7.5 to 13bar. The heavy-weight of the 

range is the CSE45V boasting a 45kW motor and working 

pressure of 7.5 to 13 bar and a delivery rate of up to 123 L/s. 

“The best way to determine which V-Series compressor 

is best for your application is to conduct an air audit. This 

will indicate the type and size of compressor to use and what 

the payback period is likely to be, thereby maximising your 

efficiency and energy savings,” said Dove. 

The V-Series incorporates an IP54 rated enclosure, Sullair 

airend technology and is backed by extended warranty 

and service options. The end result is tough design and 

premium performance suited to Australia’s hot, humid and 

often dusty conditions. 

Sullair Australia - 03 9703 9014 

mknowles@sullair.com.au 

www.sullair.com.au 


Efficient and reliable dry 

compressed air for the most 

demanding applications 

tlas Copco has launched three new desiccant air dryer ranges. 

These have been designed for efficiency with low pressure 

drops and delayed dryer cycles. Additionally, high performance 

and a constant pressure dewpoint -even at full load- are guaranteed 

under any condition. The new products include two ranges of heatless 

desiccant dryers, the CD 25+-145+ and the CD 110+-300+. According 

to Atlas Copco, the simple design and working principle guarantee 

reliability of these compact desiccant air dryers, even in harsh conditions. 

The third new range is the blower-purge dryer BD 100+-300+; 

built for energy-efficiency and endurance. By using heated ambient 

air for regeneration, this dryer range keeps the energy cost minimal. 

A desiccant air dryer protects your production, equipment and the 

quality of the end product by using desiccants to adsorb moisture from 

the compressed air. These three new desiccant air dryer ranges are 

suitable for the most demanding industries and applications like electronics, 

food and beverage, pharmaceuticals, oil and gas. 

Compressors 

Atlas Copco - 1800 023 469 

ausairinfo@au.atlascopco.com 

www.atlascopco.com.au 


101

Compressors 

Intelligent control from CompAir 

oge has recently extended the 

popular C series range of screw 

compressors up to 22 kW. The C 15 

to C 30 provide a quiet, compact and 

efficient compressed air solution to 

the medium sized compressed air 

user, setting new industry standards 

in specific power and sound pressure 

levels. 

The extended Boge C series range 

has been engineered to generate high 

free air deliveries in continuous operation 

and in an incomparably efficient 

manner. 

For maximum operating dependability 

and efficiency, all essential 

components have been integrated 

into the compact module. This serves 

to eliminate pipework and to reduce 

flow losses. 

Boge claims it has set new industry 

standards with these C series 

models in terms of low sound presompAir 

has launched the DELCOS 

XL, a built-in, easy-to-use touch 

screen controller that ensures the reliable 

and efficient operation of its rotary 

screw compressors. 

Fitted to CompAir’s L30 – L132 

range of fixed and regulated speed compressors, 

the DELCOS XL displays 

detailed system analysis, including 

network pressure and weekly average 

volume flow, in the form of on-screen 

trend diagrams and graphs, without the 

need for additional monitoring devices. 

Analysis of these trends enables users to 

set precise operating parameters for their 

compressor. The multilingual control 

system will then continuously monitor 

these settings, helping to reduce overall 

running costs. 

The controller’s real time clock enables 

users to start and stop their compressor 

at pre-set times. This allows the 

system to be pressurised prior to production, 

meaning users can have instant 

availability of compressed air. 

Reduced compressor idling 

The DELCOS XL’s second pressure setting 

matches compressor flow to plant 

demand with great efficiency. This reduces 

compressor idling and is particu- 

larly useful during periods of reduced 

production, such as the weekend, and 

when maintenance work is carried out. 

The secondary pressure setting also 

enables two DELCOS XL units to be 

sequenced without the need for additional 

equipment. 

Fast fault identification 

The controller’s service diagnostics 

feature enables compressor inputs and 

outputs to be tested, and provides quick 

identification of any faults, which can 

result in reduced downtime. 

A detailed analysis of up to 64 faults 

can be stored by the controller, providing 

information including the time, date, 

temperature and pressure of the compressor 

when each fault occurred. Integrated 

cooling and dryer controls allow the 

compressor’s cooling fan to run continuously, 

if required, and enables the dryer 

to be started before the compressor, to 

ensure it is fully functional when system 

air is required. 

Remote monitoring 

As well as on-site monitoring, the controller 

can also communicate with external 

interfaces, such as a PC, allowing for the 

remote control of the compressor. 

In the event of a power failure, the 

controller can be set to automatically 

restart the compressor, without the need 

for an operator, meaning that downtime 

is kept to a minimum. 

All of the controller’s functions are 

clearly structured within just five main 

menus on a user-friendly high-resolution 

touch screen display. A home page provides 

an instant overview of the compressor 

status, allowing users to quickly 

identify any faults. All menus can be 

code protected to eliminate any misuse 

or incorrect operation. 

CompAir (Australasia) Ltd 

039212 5800 

www.compair.com.au 

Setting the standard 

sure levels - from 63-69 dB(A) - making 

them very quiet in operation as well 

as offering increased compressed air 

outputs. The new models are also very 

energy efficient with the specific real 

demand for energy ranging from just 

7.08 – 7.16kW/m3/min (according to 

ISO1217AnexC/PN2 CPT2). 

Due to its compact design, space 

requirements are kept to a minimum. 

An installation surface of less than 

1 square metre is sufficient. A heat 

recovery system can be added to the 

new C series models as an option. Up 

to 94% of the input electrical energy is 

dissipated through the cooling medium 

(air or water) and can be recovered for 

space heating or pre-heating domestic 

water. 

The belt driven C series models up 

to 22kW are available in the standard 

pressure of 8, 10 and 13 bar. Output 

capacities range from 1.36 – 3.62 m3/ 

min and motor power 11 to 22 kW. 

The new range is also available with 

an integrated refrigerant dryer. 

BOGE Compressors (Australia) 

08 9528 2157 

www.boge.net.au 


Compressors 

Cheap choice or costly consequence 

t’s the difference between 

liability and reliability 

A leading Australian compressor 

specialist has warned 

companies to ensure the equipment 

they are buying meets 

Australian Standards. With a 

lot of international interest in 

Australia’s “booming” resource 

sector and a strong local currency, 

there has been a noticeable 

increase in companies from 

around the globe looking to 

bring a wide range of compressors 

into the market, said CAPS 

Australia’s National Product Manager 

for Air Compressors, Dino Alessio. 

“Australia has, for good reason, 

developed quite stringent standards for 

compressors. And there is now a fear 

that a number of smaller, independent 

compressor companies are bringing in 

compressors which may not meet that 

quality level,” Alessio said. 

“I have serious concerns, particularly 

on a safety level, about the performance 

and legality of some of the 

brands being imported into Australia.” 

Alessio said Compressed Air and 

Power Solutions Australia (CAPS) invests 

a lot of time and money to ensure 

the compressors it brings into country 

meet the Australian Standard. 

“It is essential for companies looking 

to acquire compressors that the 

product meets Australian Standards 

and that sometimes paying a cheaper 

price could bring a high cost burden. 

In the end: it’s the difference between 

liability and reliability.” 

He said each segment of the compressors 

imported by CAPS meets the 

highest standards of quality required 

in Australia, including: 

Wiring 

All IR compressors CAPS brought 

into the country are specially built to 

comply with Australian Standards for 

Wiring. Purchasers should note some 

products’ wiring colours vary, and do 

not meet the Australian Standards and 

are illegal to use in the workplace. 

Pressure vessels 

IR compressors CAPS are specially 

built to comply with Australian Standards 

for Pressure Vessels. The separator 

vessels are designed to AS1210. 

Again some imports may not 

meet AS1210 and are illegal to 

use in the workplace. 

MEPS2 

The IR compressors CAPS 

brought in, are built with highly 

efficient minimum energy performance 

standard (MEPS2) motors. 

While they cost CAPS more 

and have a longer lead time, it is 

illegal to run a compressor with 

a non-MEPS2 compliant motor 

in Australia. 

Capacity Testing 

The compressors are capacity tested 

in accordance with ISO 1217 annex C 

1996 (CAGIpneurop PN2CPT2). 

Noise testing 

All IR compressors are noise tested to 

ISO2151; 2004 annex C, and we state 

this in our literature. “We recommend 

companies carefully check all literature 

provided with a product to ensure there 

is full disclosure and to advise your 

prospects and customers, so they check 

the compressors’ wiring, separator 

vessel, motor and testing procedures 

to make sure they comply,” Mr Alessio 

said. 

CAPS Australia Pty Ltd 

08 6250 9800 

info@capsaust.com.au 

www.capsaust.com.au 

Realtek 




3081 

T> 03 9457 6377 

F> 03 9459 4695 

FV-S Series 

High Performance 

Vertical Machining Centres 

FH-S Series 

High Preformance 

Horizontal Machining Centres and FMS 

“World leaders in Manufacturing Technology” 



SEE US AT AUSTECH 2011 

FH 450S Horizontal Machining Centre 


103

Forum 

Finance 

Insurance cover – the real 

cost 

People rarely want to discuss life insurance, because it forces them to consider the unthinkable: the 

death or permanent disability of a loved one. Therefore just 4% of Australian families with dependants 

have sufficient cover to protect them in the event of death or disability. Addressing the underinsurance 

gap is a challenge that financial adviser networks are working to address by raising awareness of the 

need for cover and ensuring that individuals and families have the right level of protection at each stage 

of their lives, as explained by Robert Campbell of financial advisor - Armadale House. 

here are a range of circumstances 

that change a person's insurance 

needs. For this reason, personal needs 

must be reviewed regularly. Those who 

take a 'set and forget' strategy run the 

risk of being left with inadequate or inappropriate 

cover as do advisers who do 

not regularly review their client insurance 

portfolios. 

Why the underinsurance 

problem exists 

In addition to the 'set and forget' approach 

to insurance cover, there are two 

other reasons the underinsurance problem 

exists: the perceived costs and the 

effort associated with changing a policy. 

Many individuals and families are concerned 

that a change in their situation will 

result in a substantial premium increase, 

yet adequate levels of term life insurance 

for the average working Australian 

cost the same as a daily cup of coffee. In 

addition, people believe that revising a 

policy is a particularly time-consuming 

task (and to be fair, this has traditionally 

been the case). 

This type of change has required financial 

advisers to invoke a future insurability 

clause if the life insured has experienced 

one of the pre-defined events: written an 

additional policy for the increased sum 

insured, or cancelled the original policy 

and rewritten a new one. 

All of these options take time and effort, 

and all of them have limitations: 

• The future insurability clause is terrific 

if the client has met one of the pre-defined 

events stipulated in the contract. 

Unfortunately, life is not that predictable 

- and the need for addition¬al 

life insurance may be predicated by a 

number of additional factors not listed 

in the policy document 

73% of parents stated that if the main 

breadwinner of the family was unable 

to work, the family's lifestyle would be 

adversely affected 

• Writing an additional policy often 

involves questionnaires, blood tests, 

medicals and reports from doctors - all 

activities that an individual would have 

completed when they took out their 

original policy; 

• Replacing an existing policy requires 

the adviser to justify the replacement, 

which often involves a comparison of 

benefits, features, premiums and the 

claims-paying ability of the original and 

replacement policies. 

Addressing the underinsurance problem 

that currently exists in Australia requires 

a three-pronged solution. Advisers must 

continue to educate the community about 

the importance of life insurance, including 

the need for the right cover at all stages of 

life. Financial advisers also need to continue 

actively managing their clients' needs 

by reviewing their coverage regu¬larly to 

ensure their insurance remains relevant at 

each stage of their life. And finally, insurance 

companies must make it easier for 

a client to amend their cover when their 

situation changes. 

Be prepared 

• 37% of people believe life insurance 

is a low priority compared to other 

financial commitments 

• In a recent survey, 73% of parents 

stated that if the main breadwinner 

of the family was unable to work, the 

family's lifestyle would be adversely 

affected 

• The average level of term and permanent 

disability insurance in Australia is 

$162,000, compared to a suggested 

amount which is more than four times 

that figure at $517,000. 

Robert Amos of Armadale House can be 

contacted on 03 9500 0500 to provide further 

details as they relate to your situation. 

www.armadalehouse.com.au 

Armadale House Pty Ltd is an Authorised Representatives 

of Sentry Financial Planning Pty 

Ltd (AFSL 247 105) ABN 74 099 029 526 and the 

material contained in this presentation is a summary 

only and is based on information that is 

believed to be reliable. It is not our intention that 

this presentation be used by you as the primary 

source of information but as an adjunct to your 

own resources and training. No representation is 

given, warranty made or responsibility taken as 

to the accuracy, timeliness or completeness of 

any information or recommendation contained 

in this presentation and we will not be liable to 

you in contract or tort (including for negligence) 

or otherwise for any loss or damage arising as a 

result of you relying on any such information or 

recommendation (except in so far as any statutory 

liability cannot be excluded). The information and 

general advice provided do not take into account 

any person’s personal objectives, financial situation 

or needs and, because of that, you should, before 

acting on the information or advice, consider 

the appropriateness of the advice, having regard 

to your objectives, financial situation and needs 


OHS 

How to find money for OHS 

Forum 

The Principal Work Health and Safety Consultant for the Chamber of Commerce and Industry 

Queensland, Steve Griffiths, says OHS practitioners who "do their homework and speak the language of 

management" will be able to attract funding for occupational health and safety initiatives. The Chamber 

will present a free seminar at the Queensland Safety Show on 22 June that explains where to find grants 

and other funding for OHS, how to budget and be sure of a return on investment. By Marian Macdonald 

t's naïve to think employers are going 

to spend money on anything that is 

not justified, including OHS, and practitioners 

need to learn to present a powerful 

cost-benefit analysis to management. 

The good news is that the basic risk 

assessment tool so familiar to OHS practitioners 

provides a very sound foundation 

for a compelling business case for OHS investment. 

But only the foundation. A much 

more business-oriented five-step process 

is needed to build a capital expenditure 

proposal that will resonate with managers 

and employers. 

Step 1: Get hard data 

Begin with a thorough risk assessment that 

includes hard data to support your case. 

Larger businesses may already have 

their own injury data, but if that's not 

available use statistics gathered by the 

regulators and Safe Work Australia. 

The Victorian WorkCover Authority and 

Workplace Health and Safety Queensland 

publish industry hotspot information that 

will help you identify the likely areas of 

concern for your business and back that 

up with data. 

Step 2: Analyse the costs and 

benefits 

Senior managers evaluate expenditure 

proposals in terms of costs and savings. 

OHS practitioners must learn to speak 

that language. 

There's also a new legal imperative. 

From next year, the national work health 

and safety laws require employers to 

demonstrate they ensure health and 

safety as far as reasonably practicable, 

so a cost-benefit analysis is an important 

part of decision making. 

Use risk management principles that 

take frequency and severity into account 

to put a value on the risk of not under- 

taking the project. Look at it from every 

angle: work health and safety projects 

also often generate measurable savings 

in terms of productivity. 

Step 3: Prioritised 

recommendations 

No business can address every risk instantly. 

Use the risk matrix to create a 

recommended program that systematically 

addresses high-priority risks. 

Step 4: Communicate 

Don't simply email your report to management. 

Occupational health and safety 

practitioners have a responsibility to educate 

employers about risk management. 

Talk the plan through and, if necessary, 

revise your report to match management 

expectations. 

Step 5: Persevere or find 

another approach 

Many OHS initiatives that are rejected 

initially are ultimately adopted, so perseverance 

is important. On the other 

hand, there is often more than one way 

to address safety hazards and it is also 

worthwhile reviewing the risk assessment 

to consider alternative control measures. 

Employers also need to be aware of the 

industry standard for managing the hazard 

and they need to keep abreast of new 

control measures. 

Of course, a lot of safety initiatives 

require little or no capital expenditure. 

Many injuries result from unsafe behaviour 

that stems from the attitudes and 

actions of managers. Workers take their 

cue from what managers say and do, 

rather than what is in the policy handbook. 

Perhaps the most lasting investment any 

organisation can make is to ensure the 

behaviour of its managers is consistent 

with its values. 

The CCIQ presentation, Where to Find 

Money for OHS, joins a line-up of very 

practical free manufacturing and workplace 

safety seminars at the Queensland 

Safety Show. Experts will explain how to 

attract funding, what to expect from new 

WHS laws, how meet obligations manageably 

and build profitability. 

Sponsored by myosh, the Queensland 

Safety Show, Materials Handling Show and 

co-located Queensland Manufacturing 

Show run from 21-23 June 2011, at the 

Brisbane Convention & Exhibition Centre. 

For more information, visit qldsafetyshow. 

com.au, email safetyvisitor@aec.net.au or 

phone Australian Exhibitions & Conferences 

Pty Ltd on 03 9654 7773. 

New manufacturing feature for Queensland Safety Show 

The Queensland Safety Show and Queensland Materials Handling hosts a new feature: 

the Queensland Manufacturing Show, which will showcase the latest technologies 

in conventional and CNC machine tools, sheet metal working equipment, CAD/CAM 

software, programming systems and general industrial engineering products. It will 

offer thousands of visitors the opportunity to make face to face contact with major 

suppliers of the latest technologies available, as well as keeping up to date with 

work health and safety requirements. Complementing the products and services, 

the Queensland Safety Show will offer a line-up of very practical free manufacturing 

and workplace safety seminars. Experts will explain how to attract funding, what to 

expect from new OHS laws, how meet obligations manageably and build profitability 


105

Forum 

LAW 

Who owns the mould 

When entering into a manufacturing agreement with a customer, payment and ownership aspects need 

to be covered - for your protection, as explained by Paul Kirton of law firm Macpherson+Kelley. 

he physical ownership and intellectual 

property aspects of manufacturing 

agreements are often forgotten until 

disputes arise. This often occurs when 

a party terminates an agreement early 

but no-one considered what happens on 

termination, what compensation may 

be payable, and most importantly, who 

owns the physical assets and intellectual 

property created under the agreement. 

These issues were highlighted in the 

recent Federal Court case of LED Technologies 

Pty Ltd v Roadvision Pty Ltd. The case 

revolved around who owns the moulds 

and equipment purchased and made for 

the new agreement, how tooling costs are 

to be recovered by the manufacturer and 

who can use the moulds and equipment 

after termination. 

In this case, after the agreement between 

LED and its manufacturer came to 

an end, Roadvision, a competitor of LED, 

approached the manufacturer to have it 

make similar products. The manufacturer 

used some of the moulds made for LED's 

products to make Roadvision's product. 

When entering into a manufacturing 

agreement with a customer these payment 

and ownership areas need to be 

covered to protect you. 

Each deal may be different. The key is 

to discuss and agree on all terms before 

you start. 

Creating new moulds and the purchase 

of new equipment is expensive. Either 

the client or the manufacturer may bear 

all the costs or they may choose to share 

the costs. The manufacturer may bear the 

costs but amortise it across the product 

price for the volumes expected. 

Intellectual property 

The intellectual property aspects of 

the arrangement are often tangled and 

complex. The customer may hold Design 

Registration over the shape of the product, 

preventing anyone else from making 

or selling a similar product. Without 

Registration, the customer probably has 

nothing. 

The IP (predominantly copyright) in 

the mould's plans or the mould itself 

may well belong to the manufacturer (if 

it designed and made the mould) or a 

third party toolmaker. IP ownership is not 

necessarily determined by payment. It is 

often better to rely on physical ownership 

than IP rights. 

Who owns the moulds and 

equipment 

The agreement should clearly state who 

owns the moulds and equipment during 

and when the agreement ends or is terminated 

early. The fact that a party may 

have paid all, a part or an inflated product 

price does not necessarily mean they own 

the tools and equipment. 

Ownership can be structured in a 

number of ways. An example is where 

the customer is entitled to keep the 

assets if the agreement stays in effect 

until completion with the manufacturer 

keeping the equipment if the agreement 

is terminated early. Allowing a party to 

keep the equipment if the other party 

terminates the agreement early can be a 

way of ensuring that the non-defaulting 

party is able to minimise its loss. 

Amortised costs 

Commonly, costs not paid up front by the 

customer are built into the unit price of 

the item being manufactured. A manufacturing 

agreement will normally state 

the duration of the agreement and a 

minimum number of units to be provided 

each month or year. This recovery of costs 

assumes that the agreement continues 

until completion. Where disputes can 

arise is where an agreement is terminated 

early or production estimates are not met. 

If this occurs, a manufacturer may not 

have recovered all of its costs. A simple 

way to ensure that all costs are recovered 

is to ensure that the agreement contains a 

provision that a lump sum payment must 

be made by the customer to cover any 

outstanding tooling and equipment costs, 

if the agreement is terminated early. 

However, if the agreement ends early 

because the customer goes bust then 

recovery of any lump sum is unlikely. 

This may be offset by the manufacturer's 

ability to sell or use the tool, if covered in 

the Agreement. 

Who can use the equipment 

and in what circumstances 

One of the major issues in the LED case 

was which parties were entitled to use 

the moulds and in what circumstances. 

Another way for the manufacturer to recover 

costs is to be given the rights to also 

use any moulds or equipment purchased 

for themselves. 

In such circumstances, issues arise 

around the conditions on which the manufacturer 

can use the moulds. The LED case 

specifically involved issues whether the 

manufacturer was able to use the moulds 

after the agreement had ended. 

It should be made clear in any agreement 

whether the moulds or equipment 

can be used by a manufacturer both 

during and after the agreement. Common 

restrictions can revolve around the 

territories in which the manufacturer can 

distribute products made from the moulds 

or equipment, or which other parties the 

manufacturer can supply with goods made 

using the moulds or equipment. Do these 

restrictions continue if a party breaches 

the agreement 

Conclusion 

The physical ownership and intellectual 

property aspects of a manufacturing 

agreement do not need to be complicated 

but should be covered in all agreements 

with customers. A clear and encompassing 

agreement or standard Manufacturing 

Terms can save a lot of time, money and 

stress in the event of any dispute. 

Paul Kir ton, Managing Principal, 

Macpherson+Kelley. 

Ph: 03 9794 2621 

email paul.kirton@mk.com.au 

www.mk.com.au 


60 years with men and machines - Part 14 

Kate by gaslight 

We continue our regular series of instalments from the book “60 years with men and 

machines” - the autobiography of US machinist and author Fred Herbert Colvin (1867-1965). 

His first-hand experiences of those bygone days are sure to give us unique insights into the era 

which laid the foundations of the industry. It is now the turn of the century, and Fred learns 

about one of the most interesting women he has ever known 

By Fred Colvin 

One of the most interesting women 

I have ever known was the renowned 

Kate Gleason – who I met 

at the turn of the century - a kind 

of Madame Curie of machine tools; 

and at that time the only woman 

in the world connected with the 

machinery industry in a major 

sense*. Kate was an attractive 

young lady who had broken several 

of the Victorian concepts about 

woman’s place being in the home, 

and having inherited a flair for 

the mechanical from her father, 

determined to pursue a career 

that had hitherto been considered 

the exclusive domain of men with 

long beards. Instead of sitting at 

home tatting or making samplers, 

Kate spent her youth learning her 

father’s business from the ground 

up, so that when she branched out for 

herself about 1895 as a saleswoman for 

her father’s gear-cutting machines, she 

knew as much as any man in the business. 

A.H. Carpenter (who I met at the 

ASME meetings) told me the story of 

how Kate came one day to the Acme 

Machinery Company, of which he was 

the manager, intent on selling them a 

batch of Gleason gear cutters. Carpenter 

was certain that this slim young 

girl knew little or nothing about the 

product she was selling and determined 

to prove this by calling in Thompson, 

his gear expert, to test her knowledge. 

The conversation, as Carpenter remembered 

it, went something like this: 

“Well, young woman,” Thompson began, 

“tell us what you can about your 

father’s gear-cutting machines, in a 

general way at least - although I should 

warn you that I am considered something 

of an expert.” 

“I am very glad to hear that, sir,” 

said Kate demurely, “for it will make 

what I have to say that much easier.” 

“Our machines, sir, are intended for 

making bevel gears only, although like 

all other gear-cutting machines, they 

are merely specially designed milling 

or shaping machines, which, when used 

with a rotary cutter such as in our bevel-gear 

planer, fall into the milling-ma- 

chine class - a feature that gives them 

greater speed of operation and a greater 

degree of accuracy. As you know, the 

accuracy of the teeth depends upon the 

proper shaping of the teeth of the cutting 

tool, and the spacing on the accuracy 

of the indexing mechanism used, 

regardless of whether the gear teeth 

are being cut by a tool that follows a 

path established by a template, or by 

a cutter shaped to the space between 

the teeth, or by the relative motion of 

the cutter and gear. Now, on our spiral 

bevel gears. “Your what” interrupted 

Thompson, somewhat bewildered by 

Kate’s rapid-fire delivery. 

“Spiral bevel. You’re familiar with 

them, I’m sure” 

“Er ... oh, certainly, Miss Gleason 

- I’ve seen them around. I mean I’ve 

heard of them - in fact we’ve got quite 

a few spiral gears here at Acme. They 

sort of run together at an angle, don’t 

they” “Ah but those are not really 

spiral gears, you see. They are really 

spur gears with helical teeth, whereas 

true spiral bevel gears have spiral or 

curved teeth that are cut with a trepanning 

machine. And these machines 

are made only by the Gleason Works. 

You see the difference” 

“Sure - I was just thinking of the 

other type - I mean when you said spiral, 

well, a spiral is a spiral, you know.” 

“Not necessarily,” said Kate, 

with a sweet smile, “but let us go 

back to the theory of gears. If it 

were possible to have a modification 

of the spiral bevel in which 

the pinion is located below or 

above the center of the mating 

gears, what kind of gear action 

would you expect from that sort of 

arrangement” 

“Why, er ... what kind of gear 

action, you say “The action of spiral 

bevel gears under this arrangement,” 

continued Kate, ignoring 

Thompson’s embarrassment, and 

sketching with her gloved fingertip 

a few mystifying circles in the 

air, “should more nearly approach 

that of a worm drive, the location 

of the pinion permitting its shaft 

to extend beyond the gear for support 

or other reasons. Such a gear 

arrangement exists in theory only 

of course, though a few designers are 

said to be working on the problem at 

the present time,” 

“Are they .That is to say, they 

are, aren’t they” Thompson fumbled, 

beginning to wish Miss Gleason were 

back in Rochester. 

“Yes. But I really wanted to talk 

about our gear-cutting machines. Now 

first let us consider a pair of miter 

gears, where the angle of intersection 

is 45 degrees. If we . .” 

“Excuse me, Miss Gleason,” interrupted 

Thompson, mopping his brow 

with his handkerchief, “but if you don’t 

mind I would like to continue this interesting 

discussion at another time. I believe 

I have a slight touch of migraine 

coming on.” And he left the office hurriedly 

without having given Kate an 

opportunity for placing an order for 

Gleason gear cutters. 

To be continued… 

Sixty Years With Men and Machines, 

The Autobiography of Fred H Colvin, 

Master Machinist, original copyright 

1947, McGraw-Hill Publishing, reprinted 

by Lindsay Publications Inc, 1988, USA. 

*In 1914 Kate Gleason was the first 

woman elected to full membership in 

the American Society of Mechanical 

Engineers 

May 

Australian 

2011 

Manufacturing 

Australian Manufacturing 

Technology 

Technology 

May 2011 

107

Exhibition 

Calendar 2011 

INDUSTRY CALENDAR 

I N T E R N A T I O N A L 

Fabtech 

11-13 May 2011 

Mexico, Mexico city 

Includes: coil processing; plate and 

structural fabricating; punching; robotics; 

shears; tube and pipe equipment; laser and 

plasma cutting; press brakes; roll forming; 

saws and cut-off machines; tooling. 

www.fabtechmexico.com 

EASTEC 2011 Exposition 

USA, Massachusetts 


Machine tool exposition and complete 

business experience dedicated to keeping 

companies competitive. 

www.sme.org (click on “events”) 

Plastic Design & Moulding 


UK, London 

UK’s leading annual plastics event for 

plastics design and moulding 

www.pdmevent.com 

Chinaplas 


China, Guangzhou 

International exhibition for the plastics 

and rubber industries. Includes: 

ancillary equipment, blow moulding 

machines, chemicals & raw materials, 

extruders,injection moulding machines,IT 

applications/CAD/CAM, reactive resins, 

measuring, control & test equipment, 

moulds & dies, welding machines, etc 

Email: publicity@adsale.com.hk 

www.chinaplasonline.com 

Plastpol 


Poland 

International plastics and rubber processing 

exhibition 

www.targikielce.pl/index.htmlk=plastpol_en 

Email: perz.k@targikielce.pl 

Chinaplas 2011 


China, Guang Zhou 

Plastics & rubber trade fair 

www.chinaplasonline.com 

PLASTEC East 

7-9 June 2011 

USA, New York 

Plastics exhibition. Includes primary 

processing machinery, CAD and 

manufacturing, production machinery, 

materials, moulds, automation technology, 

materials handling/logistics, a full range of 

contract service providers 

www.canontradeshows.com/expo/plaste11 

InterPlas Thailand 


Thailand, Bangkok 

Plastics & rubber manufacturing exhibition 

www.interplasthailand.com 

IMTOS 


India, New Delhi 

Email: info@imtos.com 

www.imtos.com/imtos/imtos_2011.html 

Blechexpo and Schweisstec 


Germany, Stuttgart 

International trade fair for sheet metal 

processing. Supplemented with Schweisstec 

with its focus on joining technologies, 

Schweisstec will present all relevant 

mechanical and thermal joining and bonding 

techniques, as well as thermal cutting and 

welding processes. 

www.blechexpo-messe.de/en/ 

Green manufacturing expo 

USA (different dates/venues): 

7-9 June 2011 New York 

21-23 June 2011 Toronto 

20-22 Sept 2011 Rosemont 

This expo presents the full spectrum of 

sustainable manufacturing solutions and is 

part of one of the largest advanced design 

and manufacturing events in the US. Includes 

resources for long-term cost savings, improved 

process efficiency, and reduced waste. 

Email: greenmfginfo@cancom.com 

www.canontradeshows.com/expo/gmx11 

The Africa Iron Ore Conference 2011 


South Africa, Cape Town 

With a potential for West Africa production of 

iron ore to increase from near zero to more 

than 300mt pa by 2015 this conference will 

look at the challenges involved: from political 

and sovereign risks, to lack of infrastructure, 

to considerable shipping distance to the main 

customer - China. 

This strategic mining forum will bring together 

the major players 

www.immevents.com/africaironore 

IMTOS 


India, New Delhi 

Includes machine tools, heavy machinery, 

CNC machines, sheet metal working, hydraulic 

press, press brake, shearing machines, hand/ 

cutting tools, air compressors, automation, 

metrology, testing/measuring, motors & 

motor drives, welding. 

Email: info@imtos.com 

www.engimach.com/imtos/imtos_2011.html 

12th China Exhibition on sheetmetal,, 

machinery, forging, stamping and setting 

equipment 


China, Guangzhou 

(Pearl river delta - the manufacturing centre 

of China) . Includes: Sheetmetal forging, 

punching, plate shearing machines , various 

kinds of pressing machines, hydraulic 

machines, oil press, cylinder, oil cylinder, 

precision pressing machines, etc.forging press 

machines & accessories. 

www.julang.com.cn 

InterPlas Thailand 


Thailand, Bangkok 

Composites International 2011 Show (colocated); 

plastics & rubber forum, 

Includes: pre-processing/ recycling/ 

blow moulding machines, foam, reactive 

or reinforced resins, rubber processing 

equipment, rapid prototyping, bending, 

folding,edge-trimming machines etc. 

auxiliary components. 

Email: interplas@reedtradex.co.th 

www.interplasthailand.com 

Eastpo 

28 June -1 July 2011 

China, Shanghai 

Includes machine tools, turning/drilling/ 

boring/milling/grinding/deburring machines, 

machining centres, flexible manufacturing, 

gear cutting machines, ,sheet metal cutting 

machines, electrochemical machining, micro 

machining. 

Email: eastpo.net@gmail.com 

http://en.eastpo.net 

MTA Vietnam 2011 

5-8 July 2011, 

Vietnam, Ho Chi Minh City 

For the machine tool, precision engineering 

and metalworking industries. Vietnam 

imports 94% of its metalworking equipment 

and mechanical products and only 6% of 

demand is met by local manufacturers. 

Industrial production in Vietnam is growing 

at over 19% per year and imports of modern 

technology continue to increase at an annual 

30%. 

Email: atodd@oesallworld.com 

www.allworldexhibitions.com/industry. 

aspid=9 

PDMAEC 

17-20 August 2011 

Philippines, Manila 

Die & mould machinery and equipment 

exhibition. The bi-annual events incorporates 

Autocor 2011 (automation, controls, 

robotics, accessories & services exhibition), 


L O C A L 

It is recommended to contact exhibitor before attending event 

Machine Tools 2011, Metfin 2011 (metal 

finishing, equipment, tools, accessories & 

services exhibition), Metrology outsourcing 

and engineering 2011, Philplas 2011 

(plastics, machinery), Philweld 2011 and 

Sheetmetal 2011 

Email: mai_mgt@compass.com.ph 

http://pdmaec.brinkster.net/ 

COMS 2011 

(Commercialization of micro-nano systems 

conference) 

28-31 August, 2011 

USA, North Carolina 

Focuses on accelerating commercialization 

activity among established and emerging 

micro and nano businesses. Key industries 

include advanced manufacturing, 

aerospace and aviation, automotive, 

biopharmaceuticals, defence, energy. 

Email: info@ mancef.org 

http://mancef.org/COMS2011 

Vietnam Manufacturing Expo 

15-17 September 2011 

Vietnam, Hanoi 

Consists of four intl. exhibitions: InterPlas 

Vietnam (for plastics and rubber 

manufacturing,);InterMold Vietnam (for 

mould and die making,); Automotive 

Manufacturing Vietnam (for automotive 

parts manufacturing) and “Automation 

Vietnam” 

www.vietnammanufacturingexpo.com 

EMO 

19-24 September 2011 

Germany, Hannover 

Trade fair for metalworking technology. 

Includes cutting and forming machine tools, 

manufacturing systems, precision tools, 

automated materials flows, computer 

technology, industrial electronics and 

accessories. 

Email: emo@vdw.de 

www.emo-hannover.de 

4th Surat Basin Coal & Energy Conference 


Brisbane 

Focus on the Surat Basin – as huge potential 

opportunities lie within this large body of 

shallow untapped thermal coal, which is 

deemed to be greenhouse friendly. 

www.informa.com.au/suratbasin 

Austech, Ausplas, NMW 


Melbourne Exhibition Centre 

In 2011, Austech and National Manufacturing 

Week (NMW) will line up alongside Ausplas 

international plastics industry exhibition. 

Austech is the only show specifically targeted 

at the metalworking, machine tool and 

ancillary market being held in Australia in 2011. 

The conjoined shows will make the alreadycombined 

NMW/Austech Australia’s largest and 

most comprehensive industry exhibition. 

Ph: 03 9800 3666. 

Email: kwarren@austechexpo.com.au. 

www.austechexpo.com.au 

www.ausplas.com 

www.nationalmanufacturingweek.com.au 

14th Annual Global Iron Ore & Steel 

Conference & Exhibition 

Sheetmetal Industry Association (SIA) 

Industry Gala Dinner 

3 June 2011, 7pm 

NSW, Doltone House, Darling Island Wharf, 

Pyrmont 

Ticket Sales: Phone: 0413 968 964 or 

events@sheetmetalaustralia.com.au 

events@sheetmetalaustralia.com.au 

www.sheetmetalaustralia.com.au 

Queensland Safety Show/Materials Handing 


Brisbane Convention & Exhibition Centre 

Includes workplace health and safety 

solutions and services including new and 

innovative ways to improve workplace 

performance. Co-locating with Qld 

Manufacturing Show. (Debut showcase of 

the latest technologies in conventional and 

CNC machine tools, sheetmetal working 

equipment, CAD/CAM, programming systems 

and general industrial engineering products. 

Provides the opportunity of face to face 

contact with major suppliers of the latest 

technologies available, as well as keeping up 

to date with WHS requirements). 

Email safety@aec.net.au 

www.qldsafetyshow.com.au 

IAHR Congress 

26 June – 1 July 2011 

Brisbane Convention Centre 

Hydraulics in water engineering. 

IAHR is a worldwide independent 

organisation of engineers and water 

specialists working in fields related to the 

hydro-environmental sciences and their 

practical application. Activities range from 

river and maritime hydraulics to water 

resources development and eco-hydraulics, 

through to ice engineering, hydroinformatics 

and continuing education and training 

www.iahr2011.org 

Mining & Engineering WA 

5-7 July 2011 

WA, Perth 

Biennial mining industry exhibition and 

conference that focuses on the unique needs, 

challenges and opportunities facing Western 

Australia’s mining industry. 

Email: rme@reedexhibitions.com.au 

www.miningandengineeringwa.com.au 

Queensland Gas Conference & Exhibition 

16-17 August 2011 

Brisbane Convention Centre 

Examines Qld-specific Coal Seam Gas - LNG 

issues and how these relate to the broader 

domestic & international market. Focuses 

on the unique needs, challenges and 

opportunities facing Queensland’s coal seam 

gas industry. 

E: david.mccarthy@reedexhibitions.com.au 

www.queenslandgasconference.com.au 

Smart Automation 

4-6 October 2011 

Austria, Linz 

Industrial automation trade fair, contact 

platform and discussion forum and displays 

all the most intelligent solutions for 

industrial automation in Austria. 

Email: julia.tatzber@messe.at 

www.smart-automation.at 

Metalex Vietnam 

6-8 October 

Vietnam, Saigon 

Machine tools and metalworking 

technology 

www.metalexvietnam.com 

INNOVATION INSIGHTS PLANT TOUR SCHEDULE 

Innovation Insights is a program comprising on-site visits to Victorian 

manufacturing companies to showcase “Best Practice” in action. 

Each visit will be hosted by a company that has successfully implemented, 

and achieved real benefits from these practices. Offers a first-hand view of 

the improvements and provides the opportunity to speak with managers and 

employees about their experiences. 

Host Company Place Date Time 

Holden Engine Operation Port Melbourne 21 June 2011 9.00am – 12.30pm 

GlaxoSmithKline Aust. P/L Boronia 23 June 2011 9.00am – 1.00pm 

For further information on the listed plant tours contact 

Innovation Insights on the toll- free number: 1800 007 730 

Register online at: www.i2e.org.au 


109

AMTIL MEMBER PROFILE 

SUTTON TOOLS 

Headland Machinery Pty Ltd 

95 Highbury Road 

Burwood, VIC 3125 

Ph: 1300 592 061 

sales@headland.com.au 

www.headland.com.au 

Established in 1949, Headland is an Australian-owned and operated, multi-generation 

family company, with a proud history of supplying machinery equipment to the 

manufacturing and engineering sectors for more than 60 years. Headland is a leading 

supplier of machinery, software and services throughout Australia & New Zealand. 

Products include laser cutting machines, machining centres and vertical storage system. 

The purpose of Headland is to identify opportunities for our clients to improve 

their bottom line, through improved efficiencies and expanded capabilities. With a 

deep understanding of the benefits of innovative machine technology and enduring 

commitment to technical service and support, Headland has the long-term experience 

and service history for individual machinery and machinery brands. This allows 

Headland to recommend and specify manufacturing and engineering machinery, with 

a degree of authority unequalled in Australia. 

AMTIL NEW MEMBERS 

Bee Engineering P/L 

68 Killara Rd 

Campbellfield, VIC 3061 

T: 03 9357 0346 

beeeng@bigpond.net.au 

Nachi (Aust) P/L 

Unit 1, 23-29 South St 

Rydalmere, NSW 2116 

T: 02 9898 1511 

sales@nachi.com.au 

www.nachi.com.au 

CI Power 

57 Victoria St 

Fitzroy, VIC 3065 

T: 1300 247 693 

mtuke@cipower.com.au 

www.cipower.com.au 

Panelprint P/L 

34 Taylors Rd 

Croydon, VIC 3136 

T: (03) 9725 0444 

sales@panelprint.com.au 

www.panelprint.com.au 

Accessories for Manufacturing....................25 

Advanced Business Manager.......................88 

Alfex CNC......................................... 21 ,22, 45 

Amada.........................................................IBC 

AMTIL Austech........................................... 4, 5 

Applied Machinery...................................... 57 

Australian Exhibitions & Conferences.........19 

Belmatic ...................................................... 77 

Bennett Precision Tooling............................83 

Biesse Group................................................ 65 

Camplex P/L................................................. 93 

CMM Inspection & Metrology 

Solutions..................................................... 92 

DMG/Mori Seiki........................................... 39 

Export Finance and Insurance 

Corporation (EFIC)....................................... 13 

ADVERTISERS INDEX 

Enterprise Connect...................................... 30 

Farley Laser Lab........................................... 17 

FM Tool & Gauge.......................................... 59 

Haco-Kingsland Australia............................. 55 

Hare & Forbes ............................................. 63 

Idronic P/L.................................................. 101 

Iscar Australia............................................ 2, 3 

Kyocera.......................................................... 7 

Logan Office Of Economics-................... 68, 69 

LS Starrett ................................................... 78 

Machinery Forum NSW P/L.......................... 67 

Memko P/L.................................................100 

MTI Qualos .................................................. 35 

ONC CNC...................................................... 71 

Performance Waterjet................................. 86 

Punchtech Australia..................................... 82 

Purgon Engineering...................................... 96 

Quality Machine Tools................................. 53 

Realtek............................................15, 47, 103 

Recruit Australia............................................ 8 

Roaring Success........................................... 87 

Ronson Gears............................................... 89 

SECO Tooling................................................ 37 

SEI Carbide................................................... 49 

Slater Tools.................................................. 79 

Stillam.......................................................... 61 

Sutton Tools................................................. 33 

Taegutec......................................................... 9 

Tungaloy....................................................... 81 

Walter.......................................................... 41 

Winterthur Technology Group.................. OBC 

WYSIWYG..................................................... 97 


In back cover 


111

112 May 2011 Australian Manufacturing Technology 

Out Back Cover

May 2011 - Amtil

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