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A Finn-Power Publication
Americas Edition
Volume 18 Issue 1 July 2008
Finn-Power Attracts
Great Interest at
Brazilian Trade Fair
C5 Turret Punch Press
and E Press Brake
Displayed during
MECANICA See Page 19
LP Reduces Labor Costs…
See Page 4
FABTECH 2008
Las Vegas
Don’t Miss the Hottest
Show on The Strip…Or in
the Fab Shop! See Page 7
X5 Turret Displayed
at FIMAQH
South American
Fabricators Interested in
Updating Fabrication
Technology See Page 22
Integrated Automation…
See Page 12
Tech Tips
Finn-Power Part
Removal Options See Page 2
C5 Increases Production…
See Page 20
Customer Profiles
Highlight Finn-Power’s
Product Range and Flexibility
In the News…
Making
Headlines
with the
Trade Press
See Page 9
Tooling Articles…
Wila USA See Page 8
Wilson Tool
International See Page 16
Mate Precision
Tooling See Page 18

TECH TIPS
Finn-Power Part Removal Options
by Andrew McCarlie, Applications Engineer
There are many different part removal options for Finn-Power’s family
of turret punch presses, combination machines, and lasers. These
options need to be selected carefully. You should determine your
need for machine time availability versus part sorting and stacking
requirements to ensure the most efficient use of your equipment. Remember,
one operation directly affects the other. For example, overall cycle time is
increased when the machine is sorting and stacking parts, depending on the
operation and the availability of a buffering option. Depending upon part size
and hole and feature intensity, the machine may be able to produce parts
faster than the machine can buffer, sort, and stack them.
Depending upon the machine or system, the options begin with simple
manual part removal and range from fully-automated flat stacking on pallets
to automated storage systems.
Machine Part Removal Options
Manual removal and micro-jointed parts in full sheets – An example of
efficiency improvement, which is dependent upon your part removal options,
is removing parts as individual pre-cut blanks compared to nesting multiple
parts on a sheet. The result is that the unload time is for one sheet of 10
micro-jointed parts rather than 10 individual single part unloads.
Easy-Snap microjointing
– The use of
scrap-less part
retension or Easi-Snap
tools further enhance
micro-jointed part
removal by jointing
the scrap to the parts
rather than breaking
them out of the
skeleton. Nested
micro-jointed parts
can be stored and
broken out later outside of the machine cycle.
Common-line, micro-jointed nests save even more
time and give better material utilization.
Trap door to bin removal of individual part sizes
500 mm (19.5" ) square – Another part removal
option available is that of a trap door. The current size
takes a 19.5" (500 mm sq) blank. This part removal
option allows for the automatic removal of parts from
the material skeleton into a box after the last punch hit or laser cut often via
conveyor without operator intervention. Again, you must balance the
trapdoor unload time off against the extra machine cycle time that it takes up.
As an option with the Finn-Power NC Express software, the trap door can be
automatically programmed with a variable delay to stay open for all or some
parts, thereby significantly reducing the trap door cycle time. Part pickup and
The FINN-ISH LINE is a publication distributed to Finn-Power customers,
prospective customers, employees, dealers, suppliers, and friends. The staff of the
FINN-ISH LINE requests article ideas and letters for future publication.
Editor Robert J. Kolcz rjk@finnpower.com
Associate Editor Tiina Ayaydin tiina@finnpower.com
Technical Editor Lutz Ehrlich lehrlich@finnpower.com
Contributing Editor Andrew McCarlie mccarlie@finnpower.com
Senior Correspondent Timo Laurinen timo.laurinen@finn-power.com
All registered trademarks in this publication are property of their respective owners.
placement is not significantly affected by forms and holes on the part
profile and to a lesser degree material flatness.
Pick and place robots removing parts
from the sheet skeleton during part
processing and stacking on pallets.
LSR/PSR/LST – This is an option that is
typically used on punch presses and
laser/punch combination machines. The
part-picking robot typically picks a part
out of the sheet skeleton after the last
punch hit frees it from the sheet. It is then
stacked onto a pallet which can then be
feed into an automated storage system if
required. Much larger parts can be
extracted from the sheet using this option.
The time required for the robot /
unloader to extract the parts from the
sheet must be taken into account in the
overall part cycle time. Also part pickup
and placement is dependent upon the
number of cutouts and forms present on
the part profile as well as material flatness.
Pick and place robots stacking
skeleton free finished parts from a buffer
to a pallet. SGR/SBR – This unload
option can function while the machine
SG/SB is still processing parts until the
buffer is full. The parts are cut completely
from the skeleton which is cut up
allowing a truly skeleton free operation.
The finished parts are then stacked onto a
pallet which can be off-loaded manually
or attached to an automatic storage
retrieval system.
Skeleton unloader systems that
unload a full skeleton of micro-jointed
parts to a pallet such as on the Compact
Express, SG/SB/LP and Laser machines –
These unloading systems can be used as
the single main parts removal option on a
machine such as a compact express or as an extra unload option as part
of an SG or LP system. The parts can be broken out of the skeleton
outside of the machine cycle. This method of unloading is less sensitive
to material variation and part profiles.
Stacking/sorting/bin systems that stack skeleton free parts to a
pallet or bin. SG/SB STS systems – These two types of part removal
systems allow for removal of complete parts up to a certain size in the
case of the sorting bins. Both systems take time up from the processing
time to sort and stack the parts. The bin system has the advantage of
being quicker but is limited in size to 30" x59" . Scrap is tabbed to the
parts to provide for quick release and to avoid extra scrap punch hits
thereby speeding up the process cycle time. The finished part goes
directly to the next operation with no micro-joint removal.
Punch part removal using the punching slug chute – This
method can be used on all punching machines and involves using a
large rectangle (1" x3" – 25 mm x 75 mm) as a mini right angle shear
to free parts that fit inside the size of the punch. This is done by
sequencing this large rectangle to be the last hit in the punching
sequence. The freed part goes through the die down the slug chute and
out the slug conveyor. The operator diverts these slugs which are small
parts from the slug conveyor into a separate container as they fall out.
2

PRESIDENT’S CORNER
New Opportunities…New Solutions
by Tomas Hedenborg, President
When Finn-Power and Prima
Industrie S.p.A. joined forces last
February, the acquisition created
the 3rd largest sheet metal fabrication
manufacturer in the world, with a product
offering that is by far the widest in the world.
Our new group now has a turnover in excess of
400 million euros and employs 1,700 persons.
As we steadily and carefully consolidate our
many resources, we are very excited about our
ability to provide the sheet metal fabrication
world with a complete product line consisting
of machines, cells, and systems to satisfy any
customer need or requirement.
New equipment technology has always
been the lifeline to growth for sheet metal
fabricators. And the new realities of the sheet
metal fabrication industry match our combined
product lines perfectly, with a comprehensive
range of laser cutting, punching, shearing,
bending, and automation. We have designed
versatility to individual work stages by
integrating them with automated material
management and making automation as flexible
as possible. Our modular approach adapts to a
multitude of production needs and changes.
Our goal has always been to improve our
customers’ productivity.
The “Greening” of
Sheet Metal Fabrication
For the past decade, Finn-Power has
pioneered servo-electric products into the sheet
metal fabrication industry. We introduced the
first servo-electric turret punch press – the E5
work center – in 1998. Since that time, our
family of energy-saving products has grown to
include the second
generation of servoelectric
punch
presses; the LPe6
servo-electric
punch/laser
combination; the E
series servo- electric
press brake; and the EBe servo-electric Express
Bending cell.
All Finn-Power servo-electric machines
provide our customers with such benefits as:
Higher precision
Higher repeatability
Higher quality of end product
Less energy consumption (50% less than
hydraulic models)
Lower maintenance costs
Lower operating costs
Higher reliability
Ease of operation
Less noise & vibration
In the Words of Our Customers
This issue of the FINN-ISH LINE contains
several customer profile articles that highlight
Finn-Power’s product range and flexibility:
Day-Brite Lighting, Tupelo, MS, (see page
12) has earned a well-deserved reputation for
manufacturing quality industrial and
commercial lighting products. In 2004, the
company’s challenge was to find a way to go
from product design, to fabricating the part,
and have it
ready to
assemble to
within one day.
To achieve its
goal, Day-Brite
chose two Finn-
Power Shear
Genius flexible
manufacturing
cells, a Night
Train Material Management System, a robotic
hydraulic press brake, and two servo-electric E
press brakes.
“With the Shear Genius, we’ve eliminated
blanking since we are able to fabricate
full-sized sheets and nest the parts,
ensuring part consistency and squareness
from one run to the next.”
“The integration of the Night Train with
its management system was a big feature
for us. We run a great deal of 24/7,
including ‘lights out’ over the weekend
on some of our larger volume products to
get a jump on production.”
“The E Series press brake is a
phenomenal piece of equipment. With
the Finn-Power E Series press brake, we
have seen increases in our productivity,
quality repeatability, and reduced set-up
and programming times. We estimate
savings of 35-40% bending with the new
press brakes over the older models.”
“The integrated automated system was
the key to Finn-Power over the
competition. None of the other machine
producers had this capability. Finn-Power
was head and shoulders above the
competition.”
Produits Métalliques Bussières, Inc.,
Quebec, (see page 4) was formed in the early
1990s to service the growing job shop market in
3
Quebec. By 2005, the company’s old turret
punch press was overloaded, and the company
began looking at ways to increase its
productivity. After an intensive search of the
latest automated
technology on
the market,
PMB executives
chose the Finn-
Power LP6
laser/punch
combination
with the LSR
load and
stacking robot.
“Not only have we been able to bring all
the laser work in-house from the
subcontractors, but the quality is much
better with the LP6. In addition, we have
the flexibility to use either the laser or the
turret punch press.”
“The LP6 is 40% faster – and in some
cases 60% faster – than our earlier
machine. The Finn-Power LP6 /LSR has
tripled our productivity capability
compared to our earlier fabrication
equipment.”
“We also changed our production
philosophy with the new equipment. We
used to batch manufacture our parts.
With the Finn-Power equipment, we nest
everything…and this has made us more
efficient.”
Prática Technicook, Pouso Alegre, MG,
Brazil, (see page 20) is a manufacturer of
professional ovens found in grocery stores,
industrial
kitchens, and
hotels. By 2006,
the company
had outgrown
its fabrication
equipment and
needed to add
more capacity.
Prática
Technicook
chose the C5 hydraulic turret punch press from
Finn-Power which was installed in January
2007.
“Before we installed the Finn-Power C5,
we had the capacity to make six ovens per
day. With the C5, we now produce 10
ovens plus four refrigeration units per
day. We have more than doubled our
production…with less labor and less
expense in tooling.”
“95% of what we produce is stainless
steel. Everything is fabricated on the C5,
which amounts to 45 metric tons of
stainless steel per month.”

CUSTOMER PROFILE
Laser Punch Combination Increases Productivity &
Flexibility at Quebec Contract Manufacturer
“While we are a small business,
even our competitors are impressed
by our Finn-Power equipment.
When our customers see the LP6,
we gain in credibility and it gives
us increased visibility.”
In 1978, Clément Bussières founded Recouvrements Métalliques Bussières (RMB),
St. Henri de Lévis, Québec, to supply the construction industry with metal siding.
When the business first began, Bussières had only a mechanical press brake and
shear to fabricate his molding products. Soon the company grew and a sister company,
Produits Métalliques Bussières, Inc. (PMB) was formed in the early 1990s to service
the growing job shop market in Quebec. In the early days, PMB manufactured various
metal supplies mainly for the construction industry.
As the company evolved, many other industries were added to PMB’s list of
clients, including outdoor recreation, heating, transportation, agricultural controls,
electrical panels, etc. Bussières’s son Steve joined the company in 2000 with some new
ideas and a strong commitment to grow the job shop side of the business. “We bought
our first turret punch press, and a few years later purchased TIG, MIG, and spot
welding equipment to open up the subcontractor market,” explains Steve Bussières.
“Through hard work, new equipment and software procurement, and retaining our
workforce, the job shop business has grown to
80% of total sales, compared to 20% back in
2000.” Today, the company has a 24,000-
square-foot facility and 30 employees.
“A few years ago, tolerances were not as
important as they are today,” adds Dominic
Fournier, production manager. “In the past,
the tolerances were not tight with our lowtechnology
machines. But today our
customers have demanded more accurate
parts with tighter tolerances and zero defects.
We grew with our customers and this has led
to our search for quality fabrication
equipment.”
According to Bussières, by 2005 PMB’s
old turret punch press was overloaded, and
the company began looking at ways to
increase its productivity. “We also wanted to
add laser capacity,” says Bussières. “We were
subcontracting all of our laser work.”
After an intensive search for the latest
automated technology on the market, PMB
executives chose the Finn-Power LP6
laser/punch combination with the LSR load
and stacking robot. “After seeing the laser
punch in action during a Finn-Power
Technology Trip to Finland and Italy, we
knew it was the machine that filled all our
needs,” explains Bussières. “We wanted to
commit to automation, so the LP6 with the
LSR was a logical choice to allow us to
eliminate micro joints and add lights out
operation.”
The Finn-Power LP laser/punch
combination represents proven technology
and intelligent integration of punching,
forming, tapping, and laser cutting in a single
unit for the most varied sheet metal
operations. Optimum use of the Finn-Power
4
Steve Bussières (right) and Dominic Fournier, general
manager, Produits Métalliques Bussières, Inc., chose the
Finn-Power LP6 laser/punch combination with the LSR
load and stacking robot to modernize their plant and
increase productivity.

LP6 means that a fabricator can use the turret
punch press where it is easier or faster and the
laser where it is the most effective. The LP
allows the user to look at the parts to determine
the optimum process for every production.
Other benefits of the LP6 include:
Reduction of piece part costs – faster
punching time, reduction in direct labor
assigned to set up and punching, and
reduction of number of manual
operations.
Ability to utilize full sheets while
eliminating the need to shear to size
blanks being processed.
Increased machine utilization – if
load/unload system is purchased with the
LP, unmanned operation can be achieved
from load, punch, upform, laser cut,
unload, and sorting of parts in one
machine.
“The automated LP6 combination machine
has more capacity than two manual machines,”
notes Fournier, general manager. “And the LP
has dramatically reduced our labor costs. Instead
of four operators over two shifts, we now have
just two operators…and finding qualified labor
is getting more difficult each year.”
The Finn-Power LP combines the unique
C-Series 20-station turret punch press with the
latest generation of CO 2 lasers. The punching
part of the LP consists of a 30 ton (33 US ton)
turret punch press that has excellent forming
capabilities – .630" high (16 mm) with no die
interference, auto-index, Multi-Tool ® ,
programmable clamp settings, and brush tables.
Other features of the LP6 include:
A Rofin Sinar 2,500 Watt, diffusioncooled
CO 2 SLAB laser that is integrated
into the LP6.
The focal length lens can be changed in
seconds using a cartridge technique. No
tools are required. The cartridges are
available in 5" and 7.5".
“Not only have we been able to bring all the laser work
in-house from the subcontractors, but the quality is much
better with the LP6. In addition, we have the flexibility
to use either the laser or the turret punch press.”
Integration of the laser and the punch is
accomplished with the part piece flowing
from the turret punch press to the laser
without the release of the clamps. The
flow of material is from the load side to
the unload side, eliminating the timeconsuming
method of loading and
unloading from the same side.
The O-frame of the turret punch press is
separate from the laser, assuring that no
vibration will be transferred to the laser.
This provides added reliability and
uptime of the system.
Tool Holders – Finn-Power incorporates
an individual tool holder concept that
allows customers to design their own
turret layouts. Unlike other designs,
specific tool stations are not machined
into the turret. Finn-Power offers the
only flexible selection of tool holders in
the industry. Any tooling style from Mate
Precision Tooling or Wilson Tool
International can be installed in a Finn-
Power turret. Up to 10 auto-index,
forming, or Multi-Tool ® stations may be
installed in a Finn-Power turret.
Auto-Index – Finn-Power’s unique autoindex
system precisely rotates the punch
and die in their tool holders. Rotation in
.001 degree programmable increments
gives the machine the ability to rotate
beyond 360 degrees, thus allowing the
system to automatically select the shortest
path to rotate to a programmed angle
input into the NC part program with
simplicity, speed, and reliability. PMB has
six full-tonnage auto index stations.
Multi-Tool ® – Finn-Power’s Multi-Tool
stations increase the number of tools
available in a turret, thus reducing set-up
and increasing productivity. The Multi-
Tool system allows multiple tools to be
put in one station. Finn-Power Multi-
Tool offers 6, 8, 10, or 24 different
punch/die combinations in only one
station-a turret within a turret. PMB has
four Multi-Tool stations.
Upward Forming System – Finn-Power’s
upward forming option provides more
accurate forming and greater forming
heights up to 16 mm (.63" ) and 5" in
diameter. Another advantage is that all
dies are at the same height, and there are
more high-forming dies in the turret,
thus, reducing risk of material damage
and increasing machine uptime.
continued on page 6
The Finn-Power LP6 combines the unique C-Series 20-station turret punch press with the latest
generation of CO 2 lasers. Optimum use of the Finn-Power LP6 means that a fabricator can use the
turret punch press where it is easier or faster and the laser where it is the most effective. The LP6
allows the user to look at the parts to determine the optimum process for every production.
5

continued from page 5
“Not only have we
been able to bring all the
laser work in-house from
the subcontractors,” says
Bussières, “but the quality
is much better with the
LP6. In addition, we have
the flexibility to use either
the laser or the turret
punch press.”
Produits’ customers of today demand more accurate parts with tighter
tolerances and zero defects. When the subcontractors were doing the
company’s laser cutting, it facedmany quality control problems. With the
LP6, Produits controls every step of the process – from the loading of the
sheet through unloading of the part. The automation gives them a
capacity to cut stainless and polished material without scratching the part.
Loading and
Stacking Robot
The Finn-Power
loading/unloading and
stacking robot (LSR) is a material and part handling robot that can be
integrated into the LP6 laser punch. The LSR loads sheets to the laser
punch and stacks finished work pieces onto stacking pallets.
The LSR gripper has 24 suction areas, each of which can be
controlled separately. In the programming system, vacuum areas are
selected, and vacuum area values are automatically generated to the LP6
laser punch and the LSR robot.
According to Bussières, the LP6 is 40% faster – and in some cases
60% faster – than the company’s earlier machine. “We now have the
automation to run overnight,” explains Bussières. “This automation has
dramatically increased our productivity. The Finn-Power LP6 /LSR has
tripled our productivity capability compared to our earlier fabrication
equipment.”
“Prior to purchasing the Finn-Power automation, we set up teams to
train and create a new mindset for our employees,” says Fournier. “We also
changed our production philosophy with the new equipment. We used to
batch manufacture our parts. With the Finn-Power equipment, we nest
everything…and this has made us more efficient. We no longer have to
shear blanks. With the automation, we can utilize the economies of
nesting full-sized sheets.”
NC Express Programming Software
Another area of satisfaction for PMB is the Finn-Power operating
software. The NC Express CNC programming system is a user friendly,
integrated, and automated tool for managing Finn-Power equipment in
the most efficient manner. NC Express is a tooling, nesting, and
optimizing software package designed to easily integrate into an existing
manufacturing environment, taking full advantage of the CAM features
and the Finn-Power machine tool product line. “With the Finn-Power NC
Express, it is easy to nest parts with the laser and turret punch press
capacities,” explains Fournier.
New Markets
The Finn-Power automation has also opened up new markets to
PMB. “When the subcontractors were doing our laser cutting, we faced
many quality control problems,” says Bussières. “But now we control every
step of the process – from the loading of the sheet through unloading of
the part. The automation gives us the capacity to cut stainless and polished
material without scratching the part.”
While sales have continued to grow 15-20% per year at PMB with the
addition of the Finn-Power equipment, Bussières estimates his company
still has untapped capacity in the LP6. “Our target was to have this
machine handle production for the next 2-3 years by itself…and it is
almost two years since it was installed,” says Bussières. “We can continue
the same rate of growth for another two years with the LP6.”
With the difficulty in finding qualified labor, PMB is concentrating
on automation for future growth. “We are looking at robotic press brakes,”
explains Bussières. “All of our future thinking will be around automation,
including maybe the Night Train Material Management System and
another LP6. We see additional benefits every day. While we are a small
business, even our competitors are impressed by our Finn-Power
equipment. When our customers see the LP6, we gain in credibility and it
gives us increased visibility.”
6
The Finn-Power loading/unloading and stacking robot (LSR) is a material
and part handling robot that can be integrated into the LP6 laser punch.
The LSR loads sheets to the laser punch and stacks finished work pieces onto
stacking pallets.

FOCUS ON TOOLING
by David Bishop, Business Development Manager, Wila USA
Fast, Flexible & Friendly…Developing a Cost
Efficient Tooling Package for Today’s Job Shop
Purchasing a new press brake can be a pretty daunting task. And
after you’ve finally selected the press brake that you want, you’ll
have to decide which tooling system you’re going to use in your
new machine. Of course, the last thing that you’re going to want to do is
spend a small fortune on a long list of punches and dies. And you
shouldn’t have to. So, how can you get tooling for your new machine that
is fast to set up, flexible in meeting the majority of your needs, and
friendly to your budget?
The first place to start is to get assistance from someone that has a lot
of experience in tooling applications, like your local Wila regional business
development manager. He’ll help you to select a versatile set of tooling to
maximize your productivity and produce parts of the highest quality using
the smallest number of tools possible. For example, if you’re working in a
job shop environment, you’re most likely bending materials that fall within
a thickness range of 26 ga. to .250". If so, applying the following
guidelines will help you to minimize the number of tools that you’ll need
to produce a wide range of parts.
block, or die holder (whichever applies) have been installed for part
handling.
Some applications will require punches with special tip angles, and/or
special tip radii. If you are going to need them for your new press brake,
try and order them in advance of the delivery of the machine so that you
are not waiting for them after your machine arrives. Wila can normally
ship punches with modifications to the tip angles and/or radii within ten
business days following receipt of order.
Dies
When possible, use acute angle dies to air bend everything. Today’s
advanced CNC controls accurately determine the proper amount of die
penetration that is required to bend practically any material to any angle.
It is no longer necessary to purchase dies to match the included angles of
all your punches. This will eliminate the unnecessary duplication of die
openings, reduce the number of die changes that you will have to make,
and save you a lot of money.
Punches
With few exceptions, all punches should
be able to be loaded and unloaded vertically.
Sliding tooling in and out the end of the
machine is time consuming and costly.
For air bending applications, use acute
angle punches whenever possible for bending
materials of .250" (6.3 mm) in thickness and less. They are fairly strong,
have more than adequate compensation for springback with virtually all
material types, and can bend almost any angle you’ll ever need to produce
on a press brake. Some can also be used in hemming applications. They
are also lower in cost than gooseneck punches, making them less expensive
to replace when damaged.
Use gooseneck punches for bending parts that have return bends and
complicated bend sequences. Their large relief areas make them extremely
versatile and helps to reduce the need to make punch changes when going
from one part configuration to another.
When the open height allows, always select tall punches
(6" /152.4 mm and
taller) when tooling
up a new press brake
as they are always
more versatile than
short punches. As a
general rule, we
recommend that you
leave approximately 4"
(100 mm) of space
between the punch
and die after the
clamping system,
punch, die, and
crowning system, filler
Material Thickness “V” Width Angle Tons/Ft. Req. Inside Radius Min. Flange
26-20 ga. .236" (6 mm) 30 3.6 .039" (1.0 mm) .165" (4.2 mm)
18-16 ga. .394" (10 mm) 30 6.0 .066" (1.7 mm) .276" (7.0 mm)
14 ga. .630" (16 mm) 30 5.6 .105" (2.7 mm) .454" (11.5 mm)
12, 11, 10 ga. .945" (24 mm) 30 9.5 .157" (4.0 mm) .680" (17.3 mm)
.188" and .250" 1.969" (50 mm) 80 15 .328" (8.3 mm) 1.477" (37.5 mm)
Most parts can be bent with standard dies that are 2.165" (55 mm)
tall. Parts that have long down flanges require taller dies. While Wila has a
full range of standard dies that are 3.937" (100 mm) tall, they should only
be selected when required as taller dies are more expensive than short dies.
Try and use one die for each two to three material thicknesses that
you plan to bend. The following table provides some general
recommendations for the selection of a versatile range of dies to bend mild
steel in the thickness range of 26 ga. to .250"
As you can see, in most cases, you can use one die to bend two or
more material thicknesses and still get favorable results in terms of the
tonnage, inside radius, and minimum flange length requirements. In this
case, we would use a total of five dies to bend the entire range of materials
from 26 ga. to .250" . Of course, you may still need tooling for other
applications such as hemming, offset bending, large radius bending, etc.
But whatever your needs, when you combine Wila’s fast, flexible, and
friendly approach to tooling selection, you’re sure to get a cost efficient
tooling package that will pay for itself several times over the life of your
press brake.
For more information, please contact:
WILA USA
7380 Coca Cola Drive
Hanover, MD 21076 USA
Tel: 888-696-9452
Fax: 443-459-5515
Press Brake Productivity Web Site: www.wilausa.com
8

IN THE NEWS
Finn-Power in the Spotlight
Finn-Power sheet metal fabrication technology and its
customers continue to attract a great deal of attention
from trade publications throughout North & South America
CNC WEST – (December 2007/ January 2008)
This issue featured a 3-page cover article on an
installation of a Finn-Power Shear Genius, punch/shear,
Night Train material
management system,
and servo-electric
press brake
combination
machine at JB
Radiator Specialties,
Inc., Sacramento,
CA. “As we
implemented the
installation of the
Shear Genius and Night Train, we were at unprecedented volume levels at
Radiator Specialties. We were in new numbers that we had never hit before.
We would not have hit those numbers if we didn’t have the Finn-Power. We
would have had to depend on subcontractors.”
THE FABRICATOR – (April 2008)
This issue featured a 1/2-tabloid page article on the X5
turret punch press installation at Prolind Industrial,
Ltda., Sao Jose dos Campos, Brazil. “The X5 had the
best cost/ratio benefit of any of the machines that we
considered purchasing. We are
paying for the machine with
the profits that it produces. In
addition, we are no longer
using the services of the contract
manufacturer. It took only
three months with the X5 to
bring all the contracted work
in-house.”
MAQUINAS Y EQUIPOS – (May 2008)
This leading Argentine trade publication featured a
2-page article on the Shear Genius Flexible
Manufacturing Cell.
TOOLING & PRODUCTION – (May 2008)
TOOLING & PRODUCTION published a 2-page
article on the installation of two Shear Genius cells, a
Night Train
material
management
system, two servoelectric
E brakes,
and a hydraulic
robotic press brake
at Day-Brite
Lighting, Tupelo,
MS. “The
integrated
automated system
was the key to choosing the Finn-Power. None of the other machine producers
had this capability. Finn-Power was head and shoulders above the competition.
The competition had islands of automation, but the Finn-Power’s integration
of the Shear Genius and robotic press brake are all tied together with the Night
Train. It allows us to run lights out on the weekend.”
CANADIAN METALWORKING – (June 2008)
This publication featured a 3-1/2 page article on the
LP6 laser/punch combination with the LSR load and
stacking robot installed at Recouvrements Métalliques
Bussières (RMB),
St. Henri de Lévis,
Québec. “The LP6
is 40% faster – and
in some case 60%
faster – than the
company’s earlier
machine. We now
have the automation
to run overnight.
This automation has
dramatically
increased our productivity. The Finn-Power LP6 /LSR has tripled our
productivity capability compared to our earlier fabrication equipment.”
9

SOFTWARE UPDATE
NC Express ®
Finn-Power’s NC Express CNC
programming system is a user
friendly, integrated, and automated
tool for managing Finn-Power equipment in
the most efficient manner available. NC
Express is a tooling, nesting, and optimizing
software package designed to easily integrate
into an existing manufacturing environment,
taking full advantage of the powerful CAM
features and the Finn-Power machine tool
product line.
NC Express is a scalable application – the
system may be used as a single part drafting
and tooling program or as a fully-automated
machine tool management system. Either way
the results are the same – optimized automatic
N/C code creation.
The system utilizes several technologies to
create a fabrication environment in which
individual parts or assemblies of parts can be
retrieved directly from the CAD database and
processed by NC Express for random part Justin-Time
(JIT) production.
NC Express provides an easy-to-use
Windows-based Graphic User Interface. Drop
down menus and icons ensure easy interaction
with the system and immediate productivity.
This user interface, combined with NC
Express’ powerful automation capabilities
facilitates optimum production, maximizes the
computer-controlled features of the machine
tool, and simplifies the effort required to
design and program parts for production.
With the rise in material costs, labor, and
short run jobs, today’s demanding
manufacturing market is focusing more on ways
to automate the fabrication of greater quantities
of parts in less time and with fewer people. NC
Express offers a complete programming package
for Finn-Power machines that provides our
customers the ability to obtain high levels of
automation for less user interface and more
output.
by Kyle Plass, Applications & CAD/CAM Coordinator
Programming Software
GEOMETRY
The first process in programming a
component file is the geometry creation. NC
Express offers a full CAD package for
component generation. Alternatively, geometry
can also be imported from a standard DXF file
format.
Automation of importing of the geometry
can be done when using the MRP database
(OMS). Through this process, component files
can be generated from a DXF file or by using
parametric part scripting. During this process
the geometry, tooling, and storing of the
component file is accomplished.
TOOL PLACEMENT
NC Express’ Autotool will automatically
place optimal tool routines and tool placement
in accordance with the machines capabilities.
Additional automation of robot placement and
last hit orientation for unloading is set properly
for sorting of components. Any section of
tooling placed by the auto tool function can be
easily reorganized or replaced manually. Tool
placement features include:
Machine intuitive tool placement
Automatic and interactive tool placement
Automatic and interactive tool hit cycling
Automatic and interactive robot
placement
Text marking functions
NESTING
Nesting within NC Express can be done
statically or dynamically. During the nesting
process parts can be quickly moved by dragging
and dropping to the necessary location. For
quick part revisions, a single component file can
be edited at the part level and once the nest
layout is reopened the change will be promptly
updated for each part within the nest.
TRUE SHAPE NESTING
True Shape Nesting uses the true boundary
of the part as it appears in the drawing. This
allows a tighter fit between parts as compared to
rectangular nesting. True Shape Nesting allows
parts to be interlocked and provides
substantially higher material utilization.
Interactive part placement after auto nest
Automatically nest under or around the
clamps
10
Nests in zones to guarantee part accuracy
Nest in holes to gain higher sheet yield
RECTANGULAR/SHEAR NESTING
NC Express utilizes a rectangular nesting
algorithm to take advantage of the
manufacturing features of the Finn-Power Shear
Genius and Shear Brilliance. Unique features
include:
Automatic notch tooling recognition for
dynamic or static common line
Interactive Nest Tooling
Interactive Grid Nesting
OPTIMIZATION
Optimization is done automatically for all
Finn-Power machine types (punch,
shear/punch, laser/punch and laser). The
Optimizer references a pre-established tool
library verifying that all of the necessary tools to
produce the parts are available for use in the
machine’s
turret.
Once
confirmed,
machine
movement,
punching
and forming
operations, tool
changes and
sequencing are
optimized for efficient
machine operations
and throughput.
Additional
optimization features:
Automatic Repositioning and clamp
avoidance
Optimize index tooling based on angle
Automatic turret loading
Interactive optimization capabilities
Batch optimization for multiple nest
patterns
SIMULATION AND REPORTING
Full simulation of a nest will give the
programmer detailed information about how a
job will run at the machine. A full range of
reporting options will offer the programmer and
operator ample information to setup the

machine. The following are some items listed
within a report:
Tooling in a single nest or a run of nests
Nest layout
Part information
Time estimations per nest/part
KEY FEATURES
The following is a description of a few
features that help obtain the high levels of
automation within NC Express.
TEACH CYCLES
Teach Cycles allows the ability to teach
tooling, or cycled functions/routines, to a
specific geometry. A Teach Cycle is applied
when Autotool is run. The Teach Cycle works
off a given tolerance, material thickness, and
NC Express allows the setup of an exit angle
path to provide for automatic ordering of a
special tool when optimizing. This is especially
useful for a louver tool: time is saved during
part preparation and during optimization
because no additional work is needed to
manipulate the tool path within the optimized
nest.
ORDERS MANAGEMENT
SYSTEM (OMS)
NC Express comes standard with an
MRP/ERP interface to allow that customers can
control and track parts that have processed
within NC Express to be sent to the machine.
cassette. During the nesting process the user has
options to determine the layout of the cassette.
The nesting engine will nest parts based upon
stacking. This allows for NC programs to be
symmetry type. If geometry exists that has a
Teach Cycle libraried the same pattern or
tooling will be applied. The use for a Teach
Cycle can vary among machine types.
To the right, a Teach Cycle is created to
apply a cycled order of hits for a round punch -
extrusion – and a tap. This cycle will only be
used on material thickness 0.5 - 1.5 mm. The
tolerance is 0.03 mm for the hole sizes. When a
part would be Autotooled with the same type of
geometry the same exact tooling in the same
exact order will be applied throughout the part.
This eliminates the repetitive task of having to
place each of the tool hits for each and every
hole on the part.
AUTOMATIC FORM AVOIDANCE
During punching only NC Express knows
when a form exists within a nest to avoid
smashing the form by a non-form tool. Form
protection areas can be set for a special tool to
inform NC Express of the formed area on the
nest. If a non-form tool will cross the path of a
formed area within a nest, NC Express will
optimize the tool
path so that the
Ram will raise the
tool completely
up and then cross
over the formed
area avoiding the
possibility of
smashing the
form. No
additional axis moves are made in order to avoid
the form.
In addition to the form avoidance settings,
The Orders Management System is a database
in which production requirements are
determined. The parts required for production,
quantity, material codes, priorities and due dates
used to be processed for JIT fabrication. From
job shop to OEM, the OMS can benefit the
end user taking orders from the MRP/ERP and
processing them into nests.
AUTOMATIC
COMMON LINE CUTTING
For punching, shear/punch, and standalone
laser machine, NC Express offers fully
automatic common line cutting features.
Common line is activated in the nesting phase
and will help in reducing the scrap rate between
parts. Once a nest is created with parts and
tools in a common line the Optimizer will
remove excessive hits in order to avoid double
punching hits or double laser paths. Within the
shear/punch environment the nesting engine
will common line symmetrical parts, ignoring
tooling overlapping from notches. For nonsymmetrical
parts in the shear/punch
environment, the nest engine will check the
tolerance set and ignore tooling extending less
than the grid nesting tolerance.
COMPONENT
STACKING MANAGEMENT
For machine types requiring stacking of
components on a cassette, NC Express is
capable of automatically configuring the
stacking layout of the components on the
11
loaded within the machine and minimal setup
of cassettes by the operator when queuing the
NC files. The overall outcome of this feature
offers less setup time by the operator at the
machine.
For even more automation and time savings
for the programmer, if a robot exists on the
machine the user can take advantage of the
automatic robot suction cup setup via Autotool
to automate more of the process.
NEW RELEASE- V8.1
Coming soon! New version of NC Express:
Version 8.1. Major improvements include:
Multiple machines stored within one
geometry file (Binary CP)
External ERP/MRP integration
Improvements to tool hit optimization
Enhanced shear nesting/optimization
Numerous features/function additions for
laser environment (ex. new interactive
crop/scrap functions)
Various new features functions (ex. rotate
part 90° using space bar)
Die clearance setup & verification
Innovative part search function

CUSTOMER PROFILE
Day-Brite Lighting Shines Light on Integrated
Since its founding in 1923, Day-Brite
Lighting, Tupelo, MS, has earned a
well-deserved reputation for
manufacturing quality industrial and
commercial lighting products. To be sure, there
have been many changes over the years, many
lighting technology advances, and several
acquisitions – the latest being by Philips
Lighting in January 2008. Today, the company
has evolved into a major force in the lighting
industry with a facility that includes 350,000
square feet of manufacturing space and a
150,000-square-foot warehouse and 500 hourly
employees.
Perhaps one of the company’s most
dramatic changes occurred in 2002 when Day-
Brite management decided to find a better way
of manufacturing its lighting fixtures. According
to Scott Bratton, fabrication manager, Day-
Brite’s business had gradually moved away from
just commodity products to a more
architectural grade product. “The company’s
challenge was to find a way to go from product
design, to fabricating the part, and have it ready
to assemble to within one day,” explains
Bratton. “Our task was to find the best
equipment to accomplish this goal.”
Another challenge was to find fabrication
equipment productive enough to allow Day-
Brite to curb the growing amount of contract
work the company was forced to utilize local
job shops and bring it back in-house.
The Search for Automation
“Basically, we shopped around the world
looking for new equipment,” adds Charles
Philips, director, manufacturing & industrial
engineering. “We wanted to change the
direction of how we manufactured our highvolume
products at the Tupelo plant. We had to
modernize. We had two aging turret punch
presses and 11 large stamping presses with
progressive dies for high-volume runs. The dies
can cost up to $1-million and take up to six
months to produce. We had a new product line
we wanted to introduce – a high-bay fluorescent
– before our competitors did. The manufacturer
who brings its products to market first has the
advantage. So, we had to go quickly to market.”
Several Day-Brite technical teams crisscrossed
the globe searching for the fabrication
equipment. Bratton and Bob Dexter, plant
superintendent, visited Finn-Power’s facilities in
“The integrated automated system was the key to
Finn-Power over the competition. None of the other
machine producers had this capability. Finn-Power
was head and shoulders above the competition.”
Scott Bratton, fabrication manager, displays a part produced on the Shear
Genius fliexible manufacturing cell. According to Bratton, the benefits of
the Shear Genius included reduced labor costs, shorter lead times, higher
part qualify, and repeatability of that quality. The Finn-Power integrated
system allowed the company to introduce the new product to the market
for a total of $4 million in new product sales in 2005 alone.
12

Automation
Finland in October, 2002. “We saw many
facilities where multiple machines were
running with just one operator,” says
Bratton. “We decided that Finn-Power
would fit the needs at Day-Brite.”
Day-Brite began production of Phase
1 of the Finn-Power flexible manufacturing
system in September, 2004. The system
included: the Shear Genius punch/shear
combination, a hydraulic press brake with
robot, and six bays of the Night Train
material management system to tie it all
together.
Shear Genius Flexibility
With the Shear Genius concept, the
objective is to provide one machine
capable of transforming a full-sized sheet
into punched parts. These parts can be
moved to secondary operations utilizing
the sorting and stacking automation into
the Night Train material management
system and on to bending operations
without being touched by human hands.
As loading, punching, and shearing of
parts become automated, the result is
finished parts with a dramatic reduction in
scrap and manual labor while increasing
profitability.
Shear Genius functions with
sophisticated simplicity, able to perform
the most demanding jobs with minimal
set-up times and “lights out” operation.
The Shear Genius increases material
productivity through efficient and versatile
nesting programs. The level of automation
can be customized through Finn-Power’s
flexible modular solutions for raw material
storage, loading, unloading, sorting and
stacking. These features can be added later
as budgets allow and production demands
increase.
The Shear Genius ease of operation
does not compromise the cell’s per minute
part production, flexibility, or ability to
fabricate complex parts. On average, Shear
Genius reduces total manufacturing time
by 60% and saves one blank sheet out of
every 10.
The Shear Genius eliminates wasteful
skeletons and costly secondary operations,
such as deburring. Nibble edges on the
part exteriors were eliminated through the
use of the integrated right angle shear. In
fact, the same clamps that hold the sheet for
punching also hold it for shearing. In essence,
the Shear Genius allows the automated process
to begin with a full-sized sheet of material and
end with a finished part after automated
loading, punching, forming, shearing, and
unloading – all in one operation.
The Shear Genius eliminates wasteful skeletons
and costly secondary operations, such as deburring.
Nibble edges on the part exteriors were eliminated
through the use of the integrated right angle shear.
In fact, the same clamps that hold the sheet for
punching also hold it for shearing.
According to Bratton, the benefits of the
Shear Genius included reduced labor costs,
shorter lead times, higher part quality, and
repeatability of that quality. “On our older
turret punch presses, the consistency of quality
was left in the hands of our operators,” says
Bratton. “They would have to shear the blank
to a certain size and then load it into the turret
punch press. With the Shear Genius, we’ve
eliminated blanking since we are able to
fabricate full-sized sheets and nest the parts,
ensuring part consistency and squareness from
one run to the next.”
Night Train
The centerpiece of the Finn-Power
automated sheet processing system is the Night
Train Material Management System, which is
the inventory and material transporting center.
The Night Train FMS provides a total solution
for unmanned operation for sheet metal
fabricators by automating system control, as
well as material flow within the system. This
includes supplying raw material as well as
removing and storing work in process.
“The integration of the Night Train with its
management system was a big feature for us,”
says Bob Dexter, plant superintendent. “We run
a great deal of 24/7, including ‘lights out’ over
the weekend on some of our larger volume
products to get a jump on production.”
Robotic Hydraulic Press Brakes
According to Bratton, the primary focus of
the robotic hydraulic press brake was to
eliminate 2-man operations on the press brake.
“We didn’t care about keeping the robotic press
brake running 100% of the time,” says Bratton.
“Rather, we had a series of parts that required
two operators to form a complete part. With
the robot, every time we form and make that
continued on page 14
With the Shear Genius concept, the objective is to provide one machine capabile of transforming a full-size sheet into
punched parts. These parts can be moved to secondary operations utilizing the sorting and stacking automation into the
Night Train material management system and on to bending operations without being touched by human hands.
13

continued from page 13
product we save about 40%…and that’s just
labor. And I get a better part. I don’t know how
much we save from blanking because that was a
cut to size blank that we bought on the outside
Day-Brite had a series of parts that required two operators
to form a complete parts. With the robotic press brake from
Finn-Power, the company reports a labor savings of 40% of
each part bent.
to process on our older turret punch press. We
run about 500 of the 2 x 4 size a month. Our
total savings is about 50%/part.”
Other benefits of the robotic press brake
include:
Provides unmanned bending at
maximum speed
Produces exceptionally consistent parts
Can be integrated into Finn-Power’s
Flexible Manufacturing System.
Results of Phase 1
Day-Brite began production on the first
phase of the Finn-Power in September 2004
with the first shift. In December the company
added the second shift, and in February 2005 it
added the third shift. “We average
approximately 18 hours of machine uptime,”
says Dexter.
“Finn-Power’s Phase 1 introduction at Day-
Brite was a huge success,” says Bratton. “The
Finn-Power integrated system allowed us to
introduce the new product to the market for a
total of $4-million in new product sales in 2005
alone. While we hoped that the Shear Genius
would allow us to bring the contract work back
inside, we weren’t able to accomplish this at the
time because the Finn-Power system was
running at full capacity within six months.”
Phase 2 Begins
Phase 2 of the program began in March
2007 with the addition of another Shear Genius
cell; a Night Train extension of an additional
four bays; and two servo-electric E press brakes.
The new Shear Genius was the SG8 with a
maximum sheet size of 1,500 mm x 4,300 mm.
With this addition, Day-Brite brought back
75% of the fabrication that had been contracted
to local job shops. The remaining job shop
contracts mainly include laser cut parts. “Our
new Shear Genius runs nothing but pre-painted
metal, galvanized, and mirro aluminum,”
explains Bratton. “From a customer standpoint
it has helped us get products to our customers
faster. It has helped our design engineers with
product development. We dedicate our
machines and no longer have to contract
outside parts. We program the part, form the
part, and get it to them so we can now take the
product to market quickly. This has given us a
competitive edge.”
E Press Brake
The two servo-electric E press brakes have
upper and lower hydraulic tool clamping.
This Finn-Power press brake is a fast,
accurate bending solution. By applying
mechanics and electronics, a unique, patented,
mechatronic drive was developed. This drive is
based on the pulley principle resulting in a very
even distribution of forces in the top beam,
high accuracy, increased productivity, and
decreased energy consumption, and few
maintenance requirements. The frame concept
makes it possible to utilize the back gauge
system across the entire working length.
“The E Series press brake is a phenomenal
piece of equipment,” says Bratton. “Many of
our products have multiple forming operations.
With the Finn-Power E Series press brake, we
have seen increases in our productivity, quality
repeatability, and reduced set-up and
programming times. We estimate savings of 35-
40% bending with the new press brakes over
the older models.”
Reliability
Another important feature of the Finn-
Power equipment to Day-Brite has been
reliability. “We have not had any significant
downtime on the Finn-Power equipment,” says
Dexter. “The installation of the equipment went
very well. It was always on time – and when we
turned it on…it ran. Finn-Power did a very
professional job getting the equipment up and
running as well as servicing and maintaining it.”
“A key point to Day-Brite is on-time
performance to our customers,” explains
Bratton. “In 2006, we started out at 90%. Last
year, we came in at 93%, and this year our goal
is 95%. The Finn-Power equipment has helped
us reach these goals.”
“The Finn-Power integrated system allowed us to
introduce the new product to the market for a total
of $4 million in new product sales in 2005 alone.”
The two servo-electric E press brakes have upper and lower hydraulic tool clamping.
This Finn-Power press brake is a fast, accurate bending solution. With the Finn-
Power E Series press brakes, Day-Brite has experienced increases in productivity,
quality, repeatability, and reduced set-up and programming times.
“The integrated
automated system was the key
to Finn-Power over the
competition,” adds Philips.
“None of the other machine
producers had this capability.
Finn-Power was head and
shoulders above the
competition. The competition
had islands of automation, but
the Finn-Power’s integration of
the Shear Genius and robotic
press brake are all tied
together with the Night Train.
It allows us to run lights out
on the weekend. It was so
successful that we doubled the
size of the installation with a new Shear Genius,
the two E press brakes, and expanded the Night
Train. Future purchases being considered for
2009 include the EBe servo electric bender, the
X5 stand alone turret punch press, and another
E Series servo-electric press brake.”
Day-Brite’s business had gradually
moved away from just commondity
products to a more architectural
grade product. The company’s
challenge was to find a way to go
from product design, to fabricating
the part, and have it already
assembled to within one day. Finn-
Power provided the solution.
14

FOCUS ON TOOLING
by Jeff Paulson, Marketing Manager, Wilson Tool International
Improve Punch Press Performance
with Lean Tooling Innovations
Tightening budgets and rising costs are leading punch press
fabricators worldwide to develop lean manufacturing processes.
Choosing more efficient tooling can play an important role in
reaching such lean goals as faster setups, higher productivity and reduced
waste. Wilson Tool offers a number of innovative tooling solutions that
drastically improve punch press performance and help our customers
achieve their lean manufacturing goals.
Multi-Tool or Multiple Tools? You Decide.
Perhaps more than any other tooling available, the Multi-Tool
exemplifies all the benefits
that contribute to “lean”
tooling advances for the
punch press. Using a single
Multi-Tool, punch press
fabricators are able to
produce the same part in less
time and for less money than
with several individual tools.
With our Multi-Tools
for Finn-Power machines,
fabricators are able to load
the equivalent of 3, 8, or even
20 smaller tools in a single
station to increase turret capacity. So, instead of loading punches
individually, fabricators can load multiple punches simultaneously and
perform several punching operations with one set-up. This reduces the
number of tool changes operators make in the course of a run and results
in significantly less downtime.
Our R-Series Multi-Tool ® for
Finn-Power machines adds further
dimension to the flexibility offered
by multi-tools by allowing high
capacity fabricators to select not only
the punch but also the angle with a
single Multi-Tool. Using indexing, each
individual tool in a Multi-Tool is able to
achieve 360° punching operation. This flexibility
eliminates the need to purchase multiple tools shaped
at a variety of angles to meet specific production needs
thereby reducing overall tooling costs.
Unlike conventional multi-tools, our engineers created an innovative
drop-in design that allows punches to be loaded quickly and easily. They
also made sure to limit the number of moving parts, meaning our multitools
are more reliable and require less maintenance.
Bound to be the most functional tool on your punch press, the
Wilson Tool Multi-Tool increases turret capacity, reduces tool changes,
speeds run times and means less tooling to purchase and maintain.
Get Rolling with Wilson Wheels.
In pursuit of greater speed and performance, sheet metal fabricators
worldwide are discovering the Wilson Wheel ® family of products. These
revolutionary tools are unlike any other style of punch press tooling,
allowing fabricators to create unique forms and shapes at unbelievable
speeds.
Wilson Tool Helps Fabricators Reach Lean Goals
Each forming tool is specially designed for high-speed
production of slits, ribs, offsets, knurls, flares and logos
on a wide range of materials with virtually no burrs
or nibble marks. Faster cycle times and high
quality production help fabricators achieve
higher output with less waste.
Fabricators wanting the flexibility to
quickly create offsets in any contour
starting or ending anywhere on the sheet
should try the Hydraulic Rolling Offset.
Creating ribs in contours can be done
just as easily with the Hydraulic Rolling
Rib. The Hydraulic Rolling Shear
makes it possible to create straight line
cuts or contours from anywhere on the
sheet. Each of these can be produced
using Auto Index.
For easy, clean separation of parts,
the Hydraulic Rolling Pincher is ideal.
The Rolling Logo tool makes it
easy to produce more visible logos.
Logos can be produced larger
than stations size (e.g. 100 mm
long logo in a C station) on a
wide range of material. Logos
can be started or ended
anywhere on the sheet. Tonnage
is reduced compared with single
hit stamping.
Our Rolling Knurl tool
creates a grip like effect on the
sheet metal for rapid
production of knurls. Highspeed
production is equal to
programmed table travel speed.
The innovative Rolling
Flare tool enables production
of large diameter flares, even
larger than station size
normally allows, as well as
other shapes. Each Rolling
Flare is designed to suit
specific customer requirements.
Wilson Wheel technology from Wilson Tool cuts cycle times, reduces
waste and produces higher quality products to support lean manufacturing
goals.
For more information, please contact:
Wilson Tool International
12912 Farnham Avenue
White Bear Lake, MN 55110 USA
Tel: 800.328.9646
Fax: 800.222.0002
marketing@wilsontool.com
16

PRODUCT REVIEW
Discover the Unique
Versatility of Servo-Electric Punching
Finn-Power introduced the servo-electric E series turret punch press
in 1998. Since then, we have continued developing and applying
this modern, highly productive technology so that today the range
of servo-electric Finn-Power solutions is the widest in the world market, and
our experience in this technology is the most extensive. The most recent
addition is the new E5 series turret punch press.
The new generation of Finn-Power’s servo operated E-series turret punch
presses offers versatile punching, nibbling, forming and bending capacity on a
single machine tool. Based on the ECOPUNCH ® concept, the E-series is an
astonishing money saver, featuring:
Low connection power
Low power consumption
Low maintenance costs
High speed
High accuracy
High repeatability
In addition, carefully planned ergonomics, low noise levels, and a
modern industrial design combine to make the E-series turret punch press a
truly state-of-the-art solution for flexible, productive fabrication.
Three Models for Different Sizes
Finn-Power E5 – small layout and convenient operation. Max sheet size
without repositioning 50" x 120" (2,530 mm x 1,270 mm). Punching speed of
800 hpm at 1mm.
Finn-Power E6 – higher range of automation and optional features. Max
sheet size without repositioning 60" x 120" (3,074 mm x 1,542 mm).
Punching speed 900 hpm at 1mm pitch.
Finn-Power E8 – Full support for large sheet sizes. Max sheet size
60" x 169" (4,300 mm x 1,565 mm). Punching speed 900 hpm at 1mm pitch.
17

FOCUS ON TOOLING
by Andy Spence-Parsons, Marketing Manager, Mate Precision Tooling
Multi Tools Eliminate Waste
and Expand Capabilities
The implementation of lean
manufacturing techniques demands
that fabricators continually seek out
and eliminate sources of waste.
One common source of waste is the time it
takes to change tools between jobs. This can be
particularly true for a job shop manufacturer
who may have less ability to standardize on
common sizes. Multi tools help eliminate this
source of waste by allowing multiple tools to be
installed into a single station. This capability
expands the number of tools that can be
installed in a single machine set-up, reducing, or
maybe even eliminating, the necessity for tool
changes.
Mate has partnered with Finn-Power for
more than twenty years to become the world’s
leading designer and manufacturer of multi tool
systems. This valuable design partnership
resulted in a comprehensive range of world class
Multi-Tool products designed and engineered as
an integral part of the high performance
machines in which they operate.
As part of this continued relationship, Mate
recently launched a new generation of Multi
Tool assemblies that combine the flexibility and
longevity of Ultra TEC ® tooling with quick
length adjustment, and robust construction.
Ultra Multi Tools expand the capacity of a
thick turret Finn-Power punch press by allowing
either 3 or 8 punch and die sets to be placed in
one of the 3-1/2" D auto-index stations.
Designed for use with Mate’s Ultra TEC ®
punches, strippers and Slug Free ® dies, these
new multi tools enhance the high performance
of today’s thick turret Finn-Power punch presses
with the following operating features:
Ultra TEC punches provide exceptional life
between regrinds. Ultra TEC strippers have
recess for added 0.118 inch (3.00 mm) punch
grind life while the Slug Free dies eliminate slug
pulling and increase piece part quality.
The Multi Tool Drop-In quick tool change
design allows changing tools in the upper
assembly without hand tools or disassembly.
Fast tool changes reduce machine downtime
while increasing productivity.
Mate Ultra ®
Multi Tool 3
Punch and
Die Sets
The integral punch length adjustment
feature ensures optimal punching performance
and efficient slug discharge across a wide
material range. Each punch is adjustable for
precise punch-to-stripper lead and die
penetration suitable for sheet thicknesses from
0.020 inch (0.50 mm) to 0.157 inch (4.00 mm).
0.004 inch (0.10 mm) minimum die
clearance ensures unprecedented punching
accuracy and cleanly punched edges for
materials as thin as 0.020 inch (0.50 mm). The
one-piece multi tool punch carrier eliminates
cumulative tolerances to ensure punching
accuracy.
Sheet marking protection eliminates sheet
marking while improving piece part quality. The
innovative multi tool holder is designed so that
each tool is individually activated while inactive
punches are prevented from moving, thus
protecting part surfaces from unwanted marks.
A replaceable multi tool face plate reduces
ongoing maintenance costs. Its simple, robust
design provides extended service life and is fully
compatible with slide-in Ultra TEC strippers.
Mate multi tools are compatible with
automatic tool lubrication delivery systems.
Lubrication is delivered via the punch ram
through the central shaft over all moving
surfaces within the multi tool punch holder
assembly. In addition, external spiral grooves in
Mate Ultra ®
Multi Tool 8
Punch and
Die Sets
the outside diameter of the holder reduce
friction between the machine and holder,
especially during high speed nibbling
operations.
“Extending the performance of today’s high
performance thick turret presses is every Finn-
Power user’s objective,” reports Andy Spence-
Parsons, Mate VP Operations. “Mate’s new
Ultra Multi Tools, incorporating Ultra TEC
tooling, accomplishes this cost effectively while
ensuring highest quality sheet metal parts. They
are another great tooling option for fabricators
looking for a competitive advantage.”
For more information on tooling systems to
suit Finn-Power machines, please visit
www.mate.com/finn-power.
Mate Precision Tooling
1295 Lund Boulevard
Anoka, Minnesota 55303
USA and Canada
1-800-328-4492
Fax 1-800-541-0285
Outside USA and Canada
1-763-421-0230
Fax 1-763-421-0285
Email: marketing@mate.com.
18

FOCUS ON BRAZIL
Finn-Power’s Punching & Bending Technology
Attracts Interest at Brazilian Trade Fair
Last May 13-17, Finn-Power International and its
Brazilian distributor ASAMAQ jointly participated in
the MECANICA trade fair at the Anhembi Park
Exhibition Hall, Sáo Paulo, Brazil. MECANICA is one of the
largest trade shows for all of South America. And this year,
there was record-setting attendance each day of the show.
On display were Finn-Power’s C5 turret punch press and
the servo-electric E press brake. “Brazil continues to be a very
important market for Finn-Power,” explains Ron Palick, vice
president South America. “We are very pleased with the
number of visitors to our booth. We sold several machines
during the show and obtained numerous excellent leads.”
Also representing Finn-Power were Lutz Ehrlich,
punching and automation product manager, Bob Kolcz,
director, marketing & corporate communications, and Jeremy
Caddick, applications engineer.
The Finn-Power C5 turret punch press and servo-electric E press brake were visitor magnets at the Mecanica
Trade Fair, held May 13-17 in Sao Paulo, Brazil. Record setting attendance was set each day of the show.
19

CUSTOMER PROFILE
Brazilian Oven Manufacturer Heats Up
Productivity with Finn-Power Turret Punch Press
Prática Technicook, Pouso Alegre, MG, Brazil, is a manufacturer
of professional ovens found in grocery stores, industrial
kitchens, and hotels. The company began operations in 1991 as
a shelving manufacturer for the supermarket industry with a three-person
staff. Soon the Prática management identified an opportunity in
producing energy-efficient baking equipment made from quality stainless
steel material, with a better design and in accordance with governmental
hygiene regulations.
Prática’s first entry into this market was the convection oven for
baking. By 1997, the company expanded into the Combi-Oven market,
which just had been introduced to Brazil. These products roast, bake, fry,
regenerate, grill, prepare “au gratin”, and defrost. Through the years,
Prática has earned a reputation for producing quality, well-crafted
equipment – growing 40% for each of the last five years. Today, the
company’s 150 employees work two shifts in producing oven products for
18 countries throughout Latin America.
Luiz Eduardo Rosa Rezende, diretor, (left) and Alberto Close, exports manager, inspect a
part produced on the Finn-Power C5 turret punch press.
In order to increase production and productivity to meet this growing
demand, Prática recently moved into a new manufacturing facility of
5,000 square meters. The company has also examined its fabrication
equipment and techniques in order to maximize its production.
Fabrication Equipment
In its early days, Prática’s fabrication equipment consisted of a hand
shear and mechanical press brake. In 2001, the company purchased its
first punching machine – a pneumatic, one-station punch. As its market
grew, Prática added five-station hydraulic machines. By 2006, the
“The C5 has not only supplied what we
needed but has taken the job of our two
older presses. We not only increased our
production but lowered our labor costs.”
company had outgrown its fabrication equipment and needed to add more
capacity…and chose the C5 hydraulic turret punch press from Finn-Power
which was installed in January 2007.
The 20-station, 300 kN C5 hydraulic turret punch press from Finn-
Power has a maximum sheet capacity of 1270 mm x 2500 mm and is
available with either Siemens or Fanuc controls. According to Luiz
Eduardo Rosa Rezende, diretor, the C5 has proven to be highly
productive, fast, and durable. “When we purchased the Finn-Power C5
turret punch press,” explains Rezende, “our hope was to just supply our
needs with the other punch presses still in operation. However, the C5 has
not only supplied what we needed but has taken the job of our two older
presses. We not only increased our production but lowered our labor
costs.”
Features and benefits of the C5 include:
Super fast servo hydraulic punching – Nibbling speeds up to 1100
hpm. The servo-controlled ram, stroke speed, and position are fully
and individually adjustable in both directions. Another benefit is
different punching modes (punch, Quiet Punch, downforming,
and marking).
Easy loading – Four optimally-positioned gauge pins allow easy
loading of blanks or full-sized sheets. Sheet loading is performed
with a simple push and always close to the table edge. Sheet
supports rise from the table to allow easy positioning of heavy
material.
The 20-station, 300 kN C5 hydraulic turret punch
press from Finn-Power has a maximum sheet capacity
of 1270 mm x 2500 mm and is available with either
Siemens or Fanuc controls.
Finn-Power’s patented automatic clamp setting PCS is a
standard C5 feature that automatically positions sheet
clamps according to the numerical program, virtually
eliminating dead zones.
20
The C5 delivers the processed components to a freely
programmable position on the table, increasing the
operator’s efficiency.

The C5 provides nibbling speeds up to 1100 hpm.
The servo-controlled ram, stroke speed, and position
are individually adjustable in both directions.
Efficient unloading – The C5 delivers the processed components to
a freely programmable position on the table, increasing the
operator’s efficiency. The entire material flow on the C5 can be
conducted from just one side. This allows simple and efficient
logistics and enables the machine to be positioned anywhere on the
shop floor – even in a corner.
Other unique features of the C5 turret punch press include:
Tool Holders – Finn-Power incorporates an individual tool holder
concept that allows customers to design their own turret layouts.
Unlike other designs, specific tool stations are not machined into
the turret. Finn-Power offers the only flexible selection of tool
holders in the industry. Any major tooling style can be installed in
a Finn-Power turret. Up to 10 auto-index, forming, or Multi-Tool ®
stations may be installed in a Finn-Power turret.
Auto-Index – Finn-Power’s unique auto-index system precisely
rotates the punch and die in their tool holders. Rotation in .001
degree programmable increments gives the machine the ability to
rotate beyond 360 degrees, allowing the system to automatically
select the shortest path to rotate to a programmed angle input into
the NC part program with simplicity, speed, and reliability. Full
tonnage can be used in any station, with any tool size, and at
maximum material thickness. Prática has four auto-index stations.
Multi-Tool ® — Finn-Power’s Multi-Tool stations increase the
number of tools available in a turret, thus reducing set-up and
increasing productivity. The Multi-Tool system allows multiple
tools to be put in one station. Finn-Power Multi-Tool offers 6, 8,
10, or 24 different punch/die combinations in only one station – a
turret within a turret. Prática has four Multi-Tools – two 8-station
and two 10-station. The company also utilizes the Roller Ball tool
from Mate Precision Tooling. “Finn-Power’s Auto-Index and Multi
Tool are very important features for us,” says Rezende. “We have
been able to dramatically reduce our set up time with the additional
tools in the turret.”
Automatic Clamp Setting & Movement – Finn-Power’s patented
automatic clamp setting PCS is a standard C5 feature. It
automatically positions sheet clamps according to the numerical
program, virtually eliminating dead zones. When changing
production from full size to small sheets, clamp settings can be
made automatically without wasting operator time.
Optional features on the C5 include:
Optional Work Chute – Finn-Power’s work chute is not just a drop
door or a work chute in the ordinary sense. Its mechanism allows
the reception of several components to 500 mm x 500 mm in size
onto a level from which they subsequently exit from the machine.
Optional Upward Forming System – The safe solution for sheet
metal forming is from below the sheet. Finn-Power’s upward
forming option provides more accurate forming and greater forming
heights up to 16 mm.
Unique to the C5 turret punch press, full tonnage indexable
upforming allows complex forming operations to be made quickly by
using a single forming tool. An index mechanism is used to turn the
forming tool into an NC programmed angle. Finn-Power’s upforming
feature provides a precise process for knock-outs, louvers, and other
forming. Finn-Power resolved the conventional problem of the die height
impeding free sheet movement. Finn-Power’s design allows forming
heights up to 16 mm with the forms made by the die moving upwards
and then retracting, allowing completely free sheet movement, eliminating
the risk of process instability.
“We have greatly increased our capabilities with the Finn-Power C5
turret punch press,” explains Rezende. “Before we installed the Finn-Power
C5, we had the capacity to make six ovens per day. With the C5, we now
produce 10 ovens plus four refrigeration units per day. We have more than
doubled our production…with less labor and less expense in tooling. 95%
of what we produce is stainless steel. Everything is fabricated on the C5,
which amounts to 45 metric tons of stainless steel per month.”
Establishing strong relationships
with its customers and vendors is
extremely important to Prática.
“The C5 is a very accurate and
strong machine,” concludes
Rezende. “We have had no
maintenance problems and have
experienced very good after-sales
support by Finn-Power’s dealer
ASAMAQ, Limitada. When the
need arises, we would certainly buy
another Finn-Power machine.”
Pratica’s 150 employees work two shifts in producing oven
products for 18 countries throughout Latin America.
Finn-Power’s NC Express CNC programming system is a user
friendly, integrated, and automated tool for managing Finn-
Power equipment in the most efficient manner available.
Through the years, Prática has earned a reputation for
producing quality, well-crafted equipment-growing 40%
for each of the last five years.
21

FOCUS ON ARGENTINA
Finn-Power Displays X5 Turret Punch
Press at Argentina Trade Show
The FIMAQH 2008 exhibition was held May
28 - June 1 at Costa Salguero Center in Buenos
Aires, Argentina. Finn-Power International and
its Argentine distributor, Forsthuber y Sia, s.r.l. displayed
the Finn-Power X5 hydraulic turret punch press.
“While Argentina certainly has faced its share of
economic challenges in past years, the post-election
climate in Argentina is very encouraging,” says Ron
Palick, vice president, South America. “We had many
visitors each day of the show interested in updating their
fabrication technology. In fact, we sold a Shear Genius
flexible manufacturing cell during FIMAQH. The
exhibition was excellent exposure for Finn-Power in
Argentina and was proof that Finn-Power continues to
attract the South American market.”
Also representing Finn-Power were Lutz Ehrlich,
punching and automation product manager and Jeremy
Caddick, applications engineer.
Large crowd of visitors filled the Finn-Power booth each day of the FIMAQH 2008 exhibition. The point of interest
was the X5 hydraulic turret punch press that provides Finn-Power technology, performance, and reliability at an
affordable investment and operating cost.
22

FOCUS ON ROBOTICS
New Advances in
Material Handling Robotics
Robotic automation has come along way in terms of the
capability and flexibility in the last 25 years, with each year
bringing greater advancements. Some are profound, such as
Intelligent Vision Guided Robot Systems, which are dramatically changing
the way systems are being designed. Robots that can see and think.
Unheard of. Sometimes the changes are subtle but offer a huge advantage
to the customer.
The new M-10iA robot is an excellent example of how a small
improvement on an already great product can result in a large payoff for
the customer. The M-10iA is the next generation of FANUC Robotics
high-performing six-axis material handling product line. With a standard
payload of 10 kg, this robot is ideal for the quick and precise movements
required in the press brake market.
Hollow Wrist & Arm (Solution Arm)
The most impressive new feature of the M-10iA is the hollow wrist
and upper arm, also referred to as the Solution Arm. Automating a press
brake application requires a dress out or cables to be attached to the
robot’s wrist and arm. Dress-out cables are bulky when exposed and can
interfere with the robot, tooling or peripheral equipment especially when
the wrist is twisting. Complications range from damaged or twisted cables
to completely severed cables.
Failures in this area can lead
to downtime and loss of
production.
The sleek design of the
M-10iA hollow wrist and
upper arm eliminates the
need for complicated robot
dress outs and offers reduced
costs and improved reliability
in return. Dress outs, cables
and airlines are simply routed in the 50-mm hollow wrist and upper arm
and are protected. This design also brings benefits of simplified wiring of
electrical and pneumatic connections which saves integration costs. Simply
enclosing the dress out improves cable life and reliability. The hollow wrist
and arm is a unique feature of the M-10iA and is unmatched in the
robotic industry.
Doing More with the Allowable
Payload (Moments and Inertia)
Another key advantage to the M-10iA robot is that the allowable wrist
moments and inertias are significantly higher than the previous model as
well as similar class competitors’ products. The allowable wrist moment is
70% higher than the previous model and the allowable wrist inertia is
56% higher. In layman’s terms, these higher specifications allow users to
have much larger tools and allow them to have the 10kg payload offset
further away from the face of the robot. This is a key factor in the press
brake market, where the robots are required to pick and place large sheets
of sheet metal.
Long Arm Product Variant
Extremely versatile, the M-10iA is also available in a long arm version.
The benefit of the long arm requires a slight sacrifice in the payload. The
M-10iA payload decreases from 10kg to 6kg. However, if payload is not a
pressing issue, the long arm version provides a significant benefit in terms
by Kari DeSantis, Senior Marketing Analyst, FANUC Robotics America, Inc.
New M-10iA Material Handling Robot
23
of robot reach. The long arm version increases the reach from 1420mm to
1630mm. The larger work envelop can save costs by avoiding the use of
multiple robots in a cell. In addition, both the M-10iA can be mounted
on the floor, wall or ceiling at any angle.
Model Specifications
Robot Model Reach Payload
M-10iA 1420 mm 10 kg
M-10iA/6L 1630 mm 6 kg
The M-10iA represents a dominant product line with world-class axis
speeds that decrease cycle times and improve production.
Other High Performance Features & Benefits
Motion Speed Enhancements – World-class axis speeds which
result in reduced cycle times
Slimmer Arm – More compact arm for reduced interference zones
Smaller Footprint – Robot base more compact, particularly useful
for multi-arm systems
Rigid Arm – Results in improved path accuracy
Integrated iRVision – Allows visual guidance or error proofing
For more information regarding the FANUC Robotics Product line,
contact FANUC Robotics at www.fanucrobotics.com or by calling
248-377-7000.

Finn-Power Group
Sales & Service Units
Global Headquarters & Manufacturing
Finn-Power Group
P.O. Box 38
FIN-62201 Kauhava
FINLAND
Tel. + 358 6 428 2111
Fax + 358 6 428 2244
www.finn-power.com
Bending Technology Unit
Finn-Power Italia S.r.l.
Viale Finlandia 2
37044 Cologna Veneta (VR)
ITALY
Tel. + 39 0 442 413 111
Fax + 39 0 442 413 199
Benelux
Finn-Power N.V.
Leenstraat 5
B-9810 Nazareth
BELGIUM
Tel. + 32 9 382 9030
Fax + 32 9 382 9031
Canada
Finn-Power Canada, Ltd.
1040 Martin Grove Road, Unit 11
Toronto, Ontario
M9W 4W4
CANADA
Tel. +1 416 242 4431
Fax +1 416 242 7867
China
Finn-Power
Representative Office
1/F, Block 1,
Golden Dragon Ind. Centre
152-160 Tai Lin Pai Road
Kwai Chung, N.T.
Hong Kong, P.R. CHINA
Tel. + 852 2427 7991
Fax + 852 2487 5548
Finland
Finn-Power Group
P.O. Box 38
FIN-62201 Kauhava
FINLAND
Tel. + 358 6 428 2111
Fax + 358 6 428 2083
France
Finn-Power S.A.R.L.
13, Avenue Condorcet
91240 Saint Michel sur Orge
FRANCE
Tél. + 33 1 69 46 55 80
Fax + 33 1 69 46 55 81
Germany
Finn-Power GmbH
Lilienthalstr 2A
Isar-Büro-Park
Am Söldnermoos
D-85399 Hallbergmoos
GERMANY
Tel. + 49 811 55330
Fax + 49 811 1667
Spain
Finn-Power Iberica, S.L.
Crta. De Molins de Rey a Sabadell
km 13,5, Nave 5
08191 Rubi, Barcelona
SPAIN
Tel. +34 902 302 111
Fax +34 902 302 112
United States
Finn-Power International, Inc.
555 W. Algonquin Road
Arlington Heights, IL 60005
USA
Tel. + 1 847 952 6500
Fax + 1 847 952 6530
www.finnpower.com