hpt 2023 #2

ISSN 2628-5444 

high precision tooling 

Machine Tools, PCD, PVD, CVD, CBN, Hard Metal 2023 – 2 

■ Diamond coatings on cutting inserts ■ Grinding requires smart automation ■ News from LIGNA ■ 

■ New tool concept based on the Fibonacci principle ■ Filtration solutions for coatings and finish applications ■

editorial 

It doesn’t have to be Hollywood... 

Eric Schäfer 

editor-in-chief 

...when you talk about a world 

premiere. Even if everyone 

immediately thinks of the 

famous red carpet, moviestars 

from the film industry or 

the presentation of the latest 

model of an international car 

manufacturer. 

The machine and tool making 

industry, on the other hand, is a 

little more discreet when it comes to premieres, even though 

some trade fairs are a veritable fireworks display of products. 

But in the meantime, new and innovative machines are also 

unveiled as part of an event. 

In this issue of hp tooling a tool manufacturer’s trade fair 

novelty bearing the label “world premiere” can be admired 

in advance for the first time. 

And that brings us to LIGNA, the international trade show 

for woodworking and wood processing, which will finally 

be held again in Hanover in mid-May after a four-year 

break. There the tool manufacturer LEUCO will show a 

world premiere: its new tool concept based on the “Fibonacci 

principle”. The patent-pending concept for the arrangement 

of cutting edges on basic tool bodies has taken nature as its 

model when it comes to making optimum use of the limited 

space on the basic tool body. 

When it comes to producing resistant and intelligent hightech 

tools, optimized tool design plays a decisive role and 

also the appropriate choice of materials and perfect geometry. 

At the Hannover Messe the Fraunhofer IST presented a 

sustainable process chain for such tool manufacturing which 

we do not want to withhold from our readers. The subject of 

tools occupies an extensive space in this issue. So if you are 

looking not only for world premieres but also for “normal” 

innovations in the tool sector to optimize your production, 

you will here find what you are looking for. 

Eric Schäfer 


Come and see for yourself: 

www.harnisch.com 

Perfectly positioned. 

The international specialist magazines from Dr. Harnisch Publications 

You can now explore our newly designed website, with a 

clear focus on responsive design and easily usable applications. 

Alongside the free-to-use digital magazine editions, you will 

find bonus news coverage, events, subscription and 

general information on all our magazines. Take a look at 

www.harnisch.com for all relevant content. 

Our publications include: 

- Technology & Marketing -

table of contents 

cover story 

Optimal framework conditions for CFRP machining 

Piekenbrink Composite and CERATIZIT are making clean cuts 6 

materials & tools 

One milling cutter, full flexibility for all milling operations 9 

New tool concept based on the Fibonacci principle 

Innovations at LIGNA 2023 10 

Configurations extend tool life 13 

Modular tooling system for high efficiency 15 

Diamond coatings on cutting inserts 16 

Development partner for toolmakery 18 

A premium solution for hot mill roll grinding 20 

Four inserts for stator bores 21 

processes 

Sustainable process chains for the manufacture of resilient and smart tools 

Fraunhofer Institute for Surface Engineering and Thin Films IST 33 

Additive-subtractive manufacturing of clamping systems for the 

machining of CFRP components 

Fraunhofer Institute for Manufacturing Engineering and Automation IPA 34 

Design, manufacture and inspection in a smart loop 38 

Greater efficiency thanks to digital assistance systems in machine tools 39 

machining center 

Grinding requires smart automation 40 

New femtosecond laser solutions 43 

The European debut of the Supfina Fact 44 

Precise sharpening for wood and co. 45 

components 

Filtration solutions for coatings and finish applications 46 

The world’s first e-chain made entirely of recycled material 47 

The ES951 spindle and MyHSD, a high performance combination 48 

Coolant filtration as a value-adding factor 50 

news & facts 22 

fairs 5, 25 

impressum & company finder 51 

4 no. 2, May 2023

fairs in alphabetical order 

AMB Stuttgart, Germany 

(September 10-14, 2024) 

bauma Shanghai, China 

(November 26-29, 2024) 

DEBURRING Karlsruhe, Germany 

EXPO (October 10-12, 2023) 

EMO Hanover, Germany 

(September 18-23, 2023) 

EPHJ Geneva, Switzerland 

(June 6-9, 2023) 

FABTECH Toronto, Canada 

(June 11-13, 2024) 

FEIMEC São Paulo, Brazil 

(May 7-11, 2024) 

GrindingHub Stuttgart, Germany 

(May 14-17, 2024) 

GrindTec Leipzig, Germany 

(March 11-14, 2025) 

Hannover fair Hanover, Germany 

(April 22-26, 2024) 

IMTS Chicago, USA 

(September 9-14, 2024) 

JIMTOF Tokyo, Japan 

(November 5-10, 2024) 

LIGNA Hanover, Germany 

(May 15-19, 2023) 

MACH-TECH and Budapest, Hungary 

INDUSTRY DAYS (May 16-19, 2023) 

METALEX Bangkok, Thailand 

(November 22-25, 2023) 

METAV Düsseldorf, Germany 

(February 20-23, 2024) 

MOULDING Stuttgart, Germany 

EXPO (June 13-16, 2023) 

SIAMS Moutier, Switzerland 

(April 16-19, 2024) 

SIMTOS Seoul, South Korea 

(April 1-5, 2024) 

sps Nuremberg, Germany 

(November 14-16, 2023) 

Surface Stuttgart, Germany 

Technology (June 4-6, 2024) 

current status 

2024 

2024 

2023 



2024 

2024 

2024 

2025 

2024 

2024 

2024 




2024 


2024 

2024 


2024 

trade fair dates as by middle of April 2023; we are not responsible for reliability of these dates 

no. 2, May 2023 

5

cover story 

Optimal framework conditions for CFRP machining 

Piekenbrink Composite and CERATIZIT are making clean cuts 

The manufacture of premium carbon eyeglass frames has opened up a whole new segment 

for Piekenbrink Composite GmbH 

Everything seemed on the up and up for 

Piekenbrink Composite GmbH in Laupheim, Germany. 

Experts in fiber reinforced plastics, they had established 

themselves as the go-to partner for the aviation, 

automotive and mechanical engineering industries. 

However Piekenbrink CEO and, prescription eyeglass 

wearer, Björn Piekenbrink knew CFRP could do more. 

So he turned his vision into reality by partnering with 

the tool specialists at CERATIZIT and their Monster- 

Mill FRP milling cutters. 

While fiber reinforced materials are indispensable in the fields 

of aerospace, automotive and mechanical engineering, they 

also have a reputation for being difficult to work with –despite 

boasting excellent properties. The experts at Piekenbrink 

Composite GmbH in Laupheim, Germany, however, gladly 

accepted the challenge. Founded in 1979 by their father, Olaf 

and Björn Piekenbrink have transformed the company into the 

go-to partner for established aircraft and automotive manufacturers 

and mechanical engineering companies. Where 

other composite companies can go no further, Piekenbrink 

Composite only just begins. “Companies tend to either form 

fiber reinforced materials into the required shape for further 

processing or focus on subsequent drilling and milling. 

We handle everything – from tool making and model construction 

right down to the finished component, in small and 

large-scale production. We also manufacture products aimed 

at speeding customers’ manufacturing processes and ensuring 

an increased reproducibility of their carbon parts,” say 

CEOs Olaf and Björn Piekenbrink. 

Framing things differently 

So, what happens when you work day in, day out with carbon? 

“You start coming up with new ways of using the material. 

When I started wearing glasses a few years ago I had the 

immediate thought to make my frames out of CFRP,” recalls 

Björn Piekenbrink. However his optician advised against the 

idea, saying it was no easy task. “I put the idea on the back 

burner, as I didn’t really feel like putting all that effort into a 

single pair of glasses. My wife, however, was much more persistent 

and came across Friedrichs’ Spectacles, a manufacturer 

that offered carbon eyeglass frames.” That’s how Björn 

Piekenbrink finally got his carbon frames. 

The story, however, does not end there. David Friedrichs, 

the founder of Friedrichs’ Spectacles, reached out to 

Piekenbrink Composite to ask whether the company would 

be interested in manufacturing the frames for him. “He said 

he’d take care of the design and sales, while we’d take care 

of manufacturing the different models. I was on board with 

the idea as soon as he proposed it. I don’t know a thing about 

designing glasses and it didn’t feel like taking care of sales 

and marketing, but making the frames that’s right in my element,” 

says Björn Piekenbrink. And that’s how the com pany’s 


cover story 

journey into a brand-new product field began 

– one that was not without its challenges. 

CFRP/GFRP: a fine challenge 

As it turned out one of the biggest challenges 

dealt with was one of the smallest parts: the 

narrow slots in the temples, into which titanium 

hinge had to be inserted. So Piekenbrink 

reached out to CERATIZIT and asked them 

for the smallest diameter available for CFRP 

cutters. By this point Piekenbrink Composite 

and CERATIZIT had a long-standing relation - 

ship dating back to 2015 and the mutual collaboration 

continued to expand as Piekenbrink’s 

use of CNC increased. “We were drilling more 

and more and milling meters of components. 

At the time, however, there were hardly any 

tools on the market that met our high-quality 

standards, while simultaneously offering acceptable 

service life. CERATIZIT tools were 

the exception – and a game changer in my 

view,” says Björn Piekenbrink. 

When machining CFRP/GFRP, cutting edges 

are crucial. “It’s really important that nothing 

becomes delaminated during the milling process, 

which means cutting the fibers correctly 

is key. This requires extremely sharp tools, but 

also reasonable service lives. Our MonsterMill 

FRP is designed to meet precisely these requirements,” 

says Lucas Wolf, the sales representative 

at CERATIZIT, responsible for managing 

Piekenbrink’s needs. As the materials 

are very abrasive, uncoated tools are no use 

here. Also the cutting edge needs to be treated 

accordingly. Especially extreme thin diamond 

coatings, only 9 - 12 µm thick, are ideal in 

these cases as they prevent the cutting edges 

From the equipment to the manufacture of CFRP laminates 

in various colors to the machining, Piekenbrink provides 

everything from a single source 

from being rounded off unnecessarily. “We always have to find a balance between 

the coating, the cutting edge, the service life and the cut finish,” adds 

Lucas Wolf. 

MonsterMill FRP: making light work of hard fibers 

Two separate sizes of the MonsterMill FRP were used to make the eyeglass 

frames: a 0 6.0 mm cutter from the standard range for milling and profiling, 

and a special 0 3.0 mm cutter. And a 0 1.0 mm MonsterMill milling cutter 

was also used to mill the temples. Marcel Klose, head of machining at 

Piekenbrink Composite GmbH, is delighted: “Since we started using the 

MonsterMill FRP with the new diamond coating, service lives have almost 

The MonsterMill FRP from CERATIZIT 

in its element: CFRP and GFRP are 

no match for the diamond-coated cutter, 

delivering clean cuts and long service lives 

An excellent cooperation: 

Björn Piekenbrink, managing director of Piekenbrink Composite GmbH, 

Marcel Klose, head of machining at Piekenbrink and 

Lucas Wolf, sales representative at CERATIZIT 


7

cover story 

Marcel Klose: 

“Since we started using the MonsterMill FRP, 

service lives have almost doubled” 

doubled – and the cut is perfect. The benefit of having such a good cut lies 

in the fact that less reworking is needed for the final finish. As we achieve 

such a clean, sharp edge during machining, all it needs is a bit of deburring 

and then it’s done”. While it sounds minor, its impact is anything but, particularly 

when it comes to delicate components like those in carbon eyeglass 

frames. 

24/7 tool supply 

Although the MonsterMill FRP milling cutters 

offer exceptional service lives, it is still 

important to ensure optimal tool supplies 

at all times – also for all the other tools used. 

That is why Piekenbrink Composite uses the 

ToolOMat 840 from CERATIZIT. This tool 

procurement system for up to 840 different 

products is a high-tech dispensing system with 

IT integration. “Every employee in the relevant 

departments is assigned a chip that they 

can use to ‘procure’ their own tools during 

early or late shifts. This system has enabled us 

to achieve massive savings on storage. Plus we 

don’t have to take care of anything: tool supplies 

are always there and we only pay when 

the tool is actually used,” explains Marcel 

Klose. Daily tool stock management and the 

CERATIZIT replenishment service ensures 

that the ToolOMat always has the right tools 

and that they are available whenever they are 

needed. 

Björn Piekenbrink and Marcel Klose are 

also more than satisfied with the advice and 

service CERATIZIT provides. “Whenever we 

have a question or want to try out something 

new Lucas Wolf is always there to help. And it 

goes both ways: we test CERATIZIT tools and 

really put them to the test. We provide honest 

feedback on how they perform during a rigorous 

day of machining.” 

Piekenbrink deploys the MonsterMill series from CERATIZIT in 0 1.0 mm, 3.0 mm and 6.0 mm sizes 

further information: www.ceratizit.com 


One milling cutter, 

full flexibility for all milling operations 


Great tool flexibility is required when 

milling small and medium-sized 

production batches. The new 

EASYMill solid carbide endmill 

from LMT Tools combines 

maximum performance 

with universal applicability 

and sets standards in terms of 

process reliability, cost-effectiveness 

and user-friendliness. A real game 

changer for all common milling operations 

in ISO P1, P2 and M. 

LMT Tools stands for best product quality, unique solution 

expertise and technological innovations. The high performance 

tool solutions offer impressive performance as well 

as maximum process reliability. 

With the introduction of the new EASY product series 

LMT Tools expands its assortment with universally applicable 

plug-and-play tools that are characterized by maximum 

efficiency, great flexibility in application and ease 

of handling, and enable a significant reduction in process 

costs with optimum performance. The first product of 

the new EASY segment from LMT Tools is the EASYMill, 

a solid carbide milling cutter for the process-reliable machining 

of steel (e.g. case-hardened steels) and stainless 

steel materials (CrNi steels). 

Universal plug-and-play tool 

for all common milling operations 

The EASYMill features high stability as well as smooth 

milling operations with very good surface quality. Geome - 

try and coating have been specially adapted to the machining 

of low-alloy steels and austenitic materials and 

enable particularly flexible use. All common milling operations 

can be covered with just one tool – whether roughing, 

finishing, slot milling, ramping, pocket milling or 

helical plunging. The unequal helix pitch and positive 

cutting edge design reduce cutting pressure and cutting 

forces, resulting in a significant reduction in vibration. This 

also makes the EASYMill ideally suited for use on turning/milling 

machines. The adapted, sharp cutting edge ensures 

low build-up and guarantees smooth chip evacuation. 

A sticking of the chips and thus chip jams and tool breakage 

are prevented effectively. The EASYMill cuts up to the 

center and, thanks to the neck relief, enables infeed depths 

of up to three times the milling diameter. 

The new EASYMill solid 

carbide milling cutter from LMT Tools 

is a universal plug-and-play tool for all 

common milling operations in ISO P1, P2 and M 

and medium batch series as well as changing jobs. Even with 

lower-performance machines, it enables process-reliable and 

efficient milling. “The EASYMill is the result of an intensive 

analysis of customer requirements,” explains Marcus Paul, 

global head of product management at LMT Tools. “We want 

to make things as simple as possible for the customer and 

have developed a plug-and-play tool that is perfectly optimized 

for the application and meets the highest technological standards 

while offering significant cost benefits.” 

PRECISE. POWERFUL. PRODUCTIVE. 

kapp-niles.com 

further information: www.lmt-tools.com 

Best economy with optimum performance 

Excellent milling results, reduced process costs, universal 

application, uncomplicated handling: the EASYMill 

is the perfect symbiosis of top technology and economy. 

Optimized for best costs per milling meter, the new solid 

carbide milling cutter is particularly suitable for small


Innovations at LIGNA 2023 

New tool concept based on the 

Fibonacci principle 

Users can benefit in a wide variety of ways from the 

tool innovations at LIGNA 2023. For the first time at 

LIGNA, for example LEUCO will present the woodworking 

and processing industry with a completely 

new, patent-pending concept for arranging cutting 

edges on basic tool bodies. Another novelty at the 

show will be the regeneration of fixed slide milling 

cutters. 

The advantages of the various innovations are wide-ranging, 

be it reduced power consumption, longer tool life, better edge 

qualities or saving resources, etc.. 

World premiere: 

The engineers at LEUCO were inspired by nature and successfully 

transferred the Fibonacci principle to the tool world 

for the arrangement and distribution of the cutting edges on 

the basic body. The Fibonacci principle can often be found in 

nature when it comes to the optimum utilization of limited 

space. Well-known examples are the seeds of a sunflower or 

a pine cone, whose number is maximally and optimally distributed 

on the available space. Arrangement of the blades 

according to the Fibonacci principle is patent pending by 

LEUCO. This approach from bionics enriches and expands 

the companies portfolio and is used where it achieves performance 

improvements. 

At LIGNA they will present the distribution of cutting 

edges on the basic body according to the Fibonacci principle 

using several tool types, including a Z4+4 nesting cutter 

with a 0 12 mm, the jointing cutters with exchangeable cutting 

blades “SmartJointer airFace” and the p-system, and a 

disk finger cutter. The benefits for customers vary per tool 

type: the range of advantages extends from lower power 

consumption and a finer cutting pattern to higher feed rates 

and longer tool life. 



Regeneration of diamond tipped cutter: 

According to the current state of the art in the industry, 

the life cycle of a diamond-tipped cutter ends as soon as 

the cutter can no longer be resharpened due to a too low 

tipping height. Exclusively for the two market-relevant 

diamond-tipped jointing cutters “DIAMAX airFace” and 

“DIAREX airFace”, a new technical process at the company 

allows the option of brazing out the worn cutting edges, 

brazing in new cutting edges and eroding them. In short 

the user virtually receives a new tool with the existing 

basic body. The cycle provides that once a “DIAMAX 

airFace” or “DIAREX airFace” jointing cutter has been purchased, 

it remains the property of the purchaser, who then 

orders the regeneration from LEUCO, thus starting a new life 

cycle with one and the same basic body. This regeneration 

can be carried out several times. The process will be available 

in Germany for the time being after LIGNA. 

Throughfeed machining: 

performance level increased for hoggers 

From hoggers machine operators expect above all very long 

tool lives. The previous PowerTec hogger is one of the most 

widespread hoggers on the market. At LIGNA 2023 the 

company will present the new generation with new cutting 

geometry called “Powertec 5 airFace” and demonstrably 

opens up a new performance class in terms of tool life. The 

unique diameter consistency of the “Powertec 5 airFace” provides 

users with exceptional ease of use. After resharpening, 

it’s “plug & play” because, thanks to this feature, the machine 

can continue to be operated with the machine parameters 

once set. The “PowerTec 5 airFace” hoggers are used for tearfree 

and low-noise formatting of raw, melamine resin and 

paper coated, HPL, foil covered and veneered wood-based 

materials from 8 mm board thickness, when tool life performance 

and cost-effectiveness are the decisive criteria. 

Machining on CNC: 

nesting with LEUCO “DIACURVE” 

shank-type cutters 

The special feature of this type of cutter at first glance is the 

arc-shaped or curved cutting edge shape and the unusual 

design of the diamond tablets. This design is a completely 

new manufacturing and milling concept. 

Each DP cutting edge has alternating axis angles, which 

ensure perfect cut quality in the surface layers. Instead of 

many small individual cutting edges, the continuous cutting 

edges and the large, continuous chip spaces enable a very 

good chip flow. Clogging of the peripheral cutting edges is 

effectively prevented. 

The new DIACURVE nesting cutters are currently available 

in five different dimensions. These variants are suitable 

for common wood-based materials. Each tool is designed 

for a specific panel thickness range. As a global supplier 

LEUCO is also familiar with the often very different market 

conditions in the various regions of the world as well as 

the resulting requirements in terms of price, technical prerequisites 

or even user-friendliness. DIACURVE nesting cutters 

cannot be resharpened, and the purchase prices are in 

the entry-level range. A new cutter is inserted after the end of 

DIACURVE nesting cutters with 

slim diameters and large chip volume 

The t3-System milling cutter family expands 

to include a copy router, drill, grooving cutter and 

socket milling cutter 

the tool life. Machine operators therefore do not have to enter 

(error-prone) settings of the parameters in the operating panels 

of the machines, but continue “plug & play” in their work. 

Solid wood machining: 

program expansion of LEUCO t3-system insert tools 

Four applications to its patent-pending t3-system insert milling 

cutter with the cambered triangular inserts are being added 

at LIGNA 2023. The new products are designed as a nuter, 

copy cutter, drill and socket cutter. Like the t3-system end 

mill introduced in 2021, they show their strengths particularly 

in solid woods and wood-based materials. They achieve 

high-quality cuts on narrow sides, in rabbets lengthwise and 

crosswise to the grain, in free-form surfaces, and do so with 

high productivity. 

further information: www.leuco.com 


11


Focused 

Trends and innovations 

Leitz will be presenting its latest developments as 

an exhibitor at LIGNA in Hanover. This year the world 

market leader will be showing service concepts, industry 

focal points and trends from the furniture 

industry, structural timber engineering and advanced 

materials at its booth under the motto “Solutions in 

new dimensions”. The focus here is on the claim to 

further increase customer success. 

“Finding the optimally adapted solution for every requirement” 

– that is the daily incentive of the world market leader. 

Leitz sees itself as a solution provider whose products primarily 

support the increase in flexibility, efficiency and productivity 

of its customers in the relevant processes. With a total 

package of innovative tool technology, consulting, the constant 

exchange of information with all current machines and 

material manufacturers, as well as its fully comprehensive 

range of services, Leitz is the reliable partner for the wood 

and plastics processing industries all over the world. 

Focus on the furniture industry – forward-looking 

machining concepts for more flexibility 

and efficiency 

Manufacturing processes in the furniture industry are considered 

particularly complex. In some cases the industry has 

to meet the highest demands from consumers. Materials, surfaces 

and functionality, as well as different production philosophies, 

mean that the flow of daily challenges in manufacturing 

companies never stops. 

The NiRo Premium collet 

chuck made of stainless steel 

combines extremely high durability 

with great flexibility 

Leitz’s uniquely broad solution expertise ranges from panel 

sizing and trimming to edge finishing or drilling. Depending 

on the technical design of the process, whether using CNC 

machines or throughfeed machines, Leitz offers a tooling 

solution for every conceivable challenge. Leitz will be presenting 

a special highlight in Hanover with its new, innovative 

jointing concepts. They stand for maximum tool life, 

high process reliability and perfect machining quality – 

among other things with the help of the width-adjustable 

Diamaster EdgeExpert jointing cutter, which proves its durability 

every day. These are features that visitors to the 

LIGNA trade fair will be able to see for themselves in discussions 

with Leitz specialists. 

The EdgeExpert adjustable 

jointing cutters from 

Leitz are characterised 

by maximum precision, 

compact design and 

easy handling 

Focus on LeitzXPert – knowledge for your pocket 

Whether it’s the machine operator, the work preparation department 

or the foreman – in the individual processes in 

woodworking and plastics processing, questions about the 

tools used can arise again and again. In addition to the Leitz 

specialists, the LeitzXPert online application will also provide 

answers in the future. It contains tool expertise and information 

on almost all of the company’s standard products. 

Accessible free of charge the data are provided either via the 

LeitzXPert app or online via a browser-based Leitz knowledge 

platform. LeitzXPert was already presented as a study at 

LIGNA in 2019. In the meantime the application has completely 

outgrown its infancy and will be offered as a fullyfledged 

information platform in the future. Tool identification 

is very simple by entering the product ID number or via 

a QR or barcode. In addition to the product data from the 

Leitz Lexicon, the user is immediately offered additional 

product-related information, including videos. But that isn’t 

all. LeitzXPert also offers calculation programs for important 

application data in woodworking and plastics processing. 

Visitors to LIGNA can experience this new “knowledge for 

your pocket” in a hands-on way at the Leitz trade fair booth. 

Focus on CNC adaptors – competence 

in the field of tool adaptors 

Whether maximum flexibility through a quick tool change 

with the aid of a collet chuck or maximum precision through 

the use of a shrink fit chuck – Leitz will also be demonstrating 

its great expertise in the field of adaptors at this year’s 

LIGNA. The specialists from Oberkochen have the NiRo premium 

collet chuck made of stainless steel in their collection. 

An innovation that combines extremely high durability 

with great flexibility. A trapezoidal thread facilitates the 

transmission of force to the collet chuck, making it quicker 

and easier to mount shank tools. A ball-bearing ring also ensures 

that the tool does not rotate when tightening and thus 

provides the optimum hold for maximum precision during 

machining. 

further information: www.leitz.org 



Standard & custom coolant hole 

Configurations extend tool life 

The ability of the carbide cutting tools that you 

manufacture to dissipate the heat caused by friction 

is a critical part of your proprietary solution that you 

provide to your customers. 

Hyperion Materials & Technologies offers a wide range of 

standard and customizable coolant hole configurations to 

help you meet the specific performance and tool-life challenges 

of your customers. These configurations include: 

➢ central hole or parallel hole configurations 

➢ helical hole configurations 

➢ holes with lateral exit points ing 

With the ability to customize the carbide grade, number 

and shape of holes, coolant hole diameter, rod length, helix 

angle, finish and chamfer, Hyperion can provide you with the 

rod blanks that allow you to create the tools that set you apart 

from your competitors. 

further information: www.hyperionmt.com 

June 13-16, 2023


Nine cutting edges 

for higher metal removal rate 

Groove milling, cut-off milling or gear milling: 

these are just three milling processes that the circular 

interpolation milling system from Paul Horn GmbH 

carries out productively. As a true all-rounder, the 

extensive tool portfolio of this system tackles several 

other milling processes. 

It can be used from an inside 0 of 8 mm (0.315") for precise 

boring, for slot milling of narrow grooves down to a width 

of 0.25 mm (0.009"), or for milling splines: the system has 

proven to be a problem solver in numerous standard variants 

as well as in special designs for individual requirements. 

In order to further increase the chip removal volume during 

milling, Horn is expanding the circular milling system 

to include inserts with nine cutting edges. The smaller diameters 

of the system were previously available with a maximum 

of six cutting edges. Three more teeth offer further advantages. 

On one hand the production time is shortened due 

to the higher cutting feed rates that are possible, while on the 

other hand tool life is increased. In addition, the inserts run 

more quietly and with less vibration than inserts with fewer 

teeth. These advantages, in addition to the high milling 

performance of the tool system, contribute to higher overall 

efficiency and a reduction in tool costs. 

As a true all-rounder, the extensive tool portfolio of 

circular interpolation milling system from Horn tackles 

several other milling processes 

The new nine-edged milling systems M911, M913 and 

M928 are stocked in cutting widths from 1.5 mm (0.059") to 

3 mm (0.118") as standard. The maximum milling depth is 

3.5 mm (0.138") (M911), 4.5 mm (0.177") (M913) and 6.5 mm 

(0.256") (M928). The inserts are available with different coatings 

to suit the material to be machined. Due to its mass the 

solid carbide tool shank ensures vibration damping during 

milling. All variants of the tool shanks are equipped with 

an internal coolant supply. 

Horn is expanding the circular milling system with inserts that have nine teeth 

further information: www.horn-group.com 



Modular tooling system for high efficiency 

The modular system has a selection of tool holders for turrets and other tool carrier interfaces based on common machine types 

Thanks to its precision and rigidity, the modular 

tooling system from Paul Horn GmbH offers a high degree 

of flexibility for adaptation to different machine 

types. Standardized modules bridge several interfaces 

at the same time. 

The modular system has a selection of tool holders for turrets 

and other tool carrier interfaces based on common machine 

types. The matching grooving tool holders with integral coolant 

supply allow height adjustment of the cassettes and their 

mounting in the normal or overhead position, on the left 

or right side of the holder. For multi-spindle autos, height - 

adjustable tool carriers are available onto which the cassettes 

are directly screwed. The cassettes serve as an adapter 

for numerous Horn grooving insert systems. Parting off, 

grooving, sliding-head turning: the modular system can be 

flexibly adapted to the application. 

Horn is adding further variants to the modular system especially 

for use on Schütte machines. The type 850 tooling 

system supersedes the system 849. Of more compact size, the 

holder offers high stability as well as targeted cooling of the 

flank and rake face. The holder system is suitable for all sizes 

of the 315 insert system. For other inserts, HORN offers corresponding 

special solutions. The tool holders are available 

with and without angle adjustment. Height adjustment is 

simple and easily accessible from the front. The tool system is 

compatible with the Schütte series ECX, SCX and ACX. 


RECYCLED 

PACKAGING 

IS KING 

PACK. USE. RECYCLE. REPEAT. 

Push the king off his throne? 

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Diamond coatings on cutting inserts: 

Alsameca special tools only with 

premium coatings from CemeCon 

Automotive, aerospace, medical technology 

– high-tech industries depend on first-class precision 

tools for the process-reliable, high-precision 

and, last but not least, economical production 

of their components from materials that are often 

difficult to machine. Alsameca from the French 

town of Lutterbach (Haut-Rhin) has made a name 

for itself in these industries with high-quality cutting 

tools. When it comes to finding solutions for 

special application, the company works closely 

with the coating expert CemeCon – for example in the 

field of diamond-coated cutting inserts. 

Anyone who enters Alsameca’s production facility is immediately 

struck by the ultra-modern machinery, in addition 

to the cleanliness and obvious love of order. Automated 

grinding centers, robot-controlled test benches, optimized 

production management – the manufacturer of precision tools 

and regrinding service spares no expense or effort to ensure 

the quality of its products and at the same time a rapid 

responsiveness. The goal is to “increase our productivity, gain 

market share and remain competitive,” says Pascal Guichard, 

founder and director of the ASP group, which includes 

Alsameca. For this he is constantly investing in automation 

and digital technologies. In 2008 Alsameca joined the ASP 

(Affûtage Service Performance) group with a total of 49 employees. 

ASP is known for its versatility in grinding and in 

the production of cutting tools and wear parts (solid carbide, 

brazed carbide or high-speed steel). 

Whether shank tools or cutting inserts – diamond coatings 

from CemeCon open up potentials in the machining of 

composites, graphite and non-ferrous metals 

Alsameca has been grinding precision tools for 42 years – 

today with 19 employees around 140,000 tools annually – and 

has designed many sophisticated solutions for a wide range of 

industries. The experts know exactly how important the interaction 

of substrate, cutting-edge geometry and coating is. 

ASP has its own PVD coating expertise in-house and uses it 

successfully mainly for standard tools. Precision tools for special 

applications, for first-class premium coatings, Alsameca 

additionally relies on the experience of CemeCon. 

Stéphane Kalt, 

Director of Alsameca: 

“With CemeCon’s 

diamond coatings, for 

example, we have been 

able to signifi cantly 

increase the 

performance of our 

cutting inserts – both 

in terms of tool life and 

machining quality.” 

Machining lightweight materials 

with diamond-coated cutting inserts 

Alsameca cutting inserts score with exceptional cutting-edge 

geometries, multi blade configuration and high feed rates. 

“With their nanocrystalline, extremely smooth and hard 

surfaces, our CCDia® coatings are superior to other coating 

solutions in terms of performance, quality and precision and 

contribute significantly to even higher efficiency. Especially 

on cutting inserts for machining CFRP and GFRP, graphite, 

non-ferrous metals or plastics, CCDia® coatings open up 

enormous potentials,” says Jean Cariolini, sales Europe at 

CemeCon. The powerful combination of Alsameca’s cutting 

inserts and CemeCon’s diamond coatings achieves excellent 

results when machining lightweight materials for the automotive 

and aerospace industries. 

Matching all the parameters in a joint engineering approach 

of CemeCon and Alsameca made this happen. The experts 

coordinate the coating precisely with the requirements 

and application in a close dialogue. Substrate, geometry 

and coating all together form an optimal machining solution 

for the respective application – perfect for Alsameca’s sophisticated 

tool concepts and special applications. 

Service life significantly increased 

Stéphane Kalt, director of Alsameca: “Whether dedicated 

diamond coatings for our cutting inserts or high-performance 

HiPIMS coatings for special applications – we have 

already worked with CemeCon in many successful engineering 

projects and are always very satisfied with the results and 

with the speed of implementation. With CemeCon’s diamond 

coatings, for example, we have been able to significantly 

increase the performance of our cutting inserts – both in 

terms of tool life and machining quality.” 

further information: www.cemecon.com 


CBN grinding discs for highest quality requirements 

Small, but powerful 


Small CBN grinding discs 

25 millimeters – the size of a two-Euro coin – is the 

diameter of the new CBN grinding discs developed 

by Liebherr-Verzahntechnik GmbH specifically for 

machining critical component geometries with low 

tool overrun. They can be coated with specifically selected 

grain for longer service life and faster grinding 

processes. 

Alongside diamond, CBN (cubic crystalline boron nitride) is 

one of the hardest grinding materials available. CBN grinding 

discs are suitable for the highest quality requirements 

because they are dressing-free, wear-resistant and heat-resistant. 

Liebherr has developed very small CBN grinding discs 

with a diameter of just 25 millimeters for gears subject to 

collision and with low tool overrun. The company is therefor 

extending the geometric process limits for internal and external 

gears with interfering contours. 

CBN expertise at Liebherr 

CBN grinding discs have a steel body which is electro- plated 

with abrasive CBN grains. The basic steel body is breakresistant 

and can be reused several times. However, the 

manu facturing process is complex, especially when making 

very small discs. With more than 30 years of CBN expertise, 

Liebherr has the necessary know-how to manufacture the 

grinding discs completely in-house. 

Optimized design 

The smaller the discs, the more complicated they are to 

manu facture: “In this size range the process has no margin 

for error,” explains Haider Arroum, head of sales for gear 

cutting tools at Liebherr. “And you also have to choose the 

right grain size to achieve the desired surface roughness of 

the workpiece while generating as little wear as possible, even 

at high rotary and cutting speeds.” Liebherr’s special design 

allows for shorter and more economical grinding processes. 

Successful in the aerospace industry 

The tiny discs are already being successfully used by 

Liebherr-Aerospace for profile grinding of small gears for 

planetary gear trains. “They’re very happy with the results. 

And as expected, both the quality and the cost-effectiveness 

were excellent – an important factor in this area in particular,” 

says Haider Arroum. 

further information: www.liebherr.com 


17


Boehlerit – the independent development partner 

for toolmaker 

Since 1932 Boehlerit has been a pioneer in the 

production of carbide. Today the standard portfolio 

includes more than 70 cutting-edge carbide grades, 

which are used by almost all well-known toolmakers 

for a wide range of applications. In addition as a development 

partner for toolmakers, the company from 

Kapfenberg with its decades of experience, offers the 

development of individual carbide grades, coatings 

and geometries. In this way real machining innovation 

often begins in Boehlerit’s own powder production. 

Compared to the past, modern carbides are characterised 

by more uniform microstructures. This is primarily due to 

the higher purity of the raw materials, but above all also to 

more uniform sintering conditions in modern production 

facilities. 

High metallurgical flexibility for 

individual tool developments 

Boehlerit’s metallurgy center, with its own powder production, 

has for decades been the hub for the development of innovative 

cutting materials. Over 10,000 m 2 of production 

space offer maximum metallurgical flexibility for the production 

of indexable inserts and blanks as well as for the provision 

of carbide granulate for toolmakers. The dynamic FEM 

calculation for the digital customer-specific design of modern 

tool systems is supportive here. 

Boehlerit is an independent carbide specialist in the tool 

industry and a close development partner for toolmaker. 

In its cooperation with toolmakers, the family-run company 

guarantees direct collaboration between technologists with 

discretion and product protection. “When you work as a 

long-term partner with almost all well-known tool manufacturers, 

trust is the order of the day”, emphasises Dr. 

Christian Kolbeck, head of segment wear parts & toolmaker. 

However Boehlerit is not only a technological pioneer and 

one of the world’s leading manufacturers of carbide cutting 

materials for tools used in metal, wood and plastics processing, 

but also ethical. Only carbides made exclusively from 

conflict-free raw materials are produced. This ethically justifiable 

procurement of materials and raw materials has been 

one of the pioneering elements of the company’s compliance 

culture for many years. 

State-of-the-art production and coating processes 

The continuous development of production processes using 

state-of-the-art production equipment plays a major role in 

the carbide expertise. This includes the latest servo-electric 

powder presses, which offer the highest reproducibility and 

dimensional accuracy and enable the production of highly 

complex geometries. 

Dr. Christian Kolbeck, 

head of segment wear parts & toolmaker 

A special feature among the presses at Boehlerit is one of 

the largest carbide presses with a pressing force of 650 t. 

Cubic and round parts with a surface area of up to 250 cm 2 

are pressed economically and in series production on this 

press. All in all the production range extends from the smallest 

carbide part weighing a few tenths of a gram to large parts 

weighing more than 100 kg. The tools for this are made in the 

company’s own press tool shop. This guarantees μm-precise 



Boehlerit procured a new 5-axis hard milling 

machine, which now performs milling, grinding 

and testing in one clamping and replaces 

the EDM technology previously used for this 

purpose in this area. Particularly in coating 

technology – one of the company’s core compe - 

tences – investments are naturally made on an 

ongoing basis. In addition to the latest PVD 

technology (HiPIMS), Boehlerit is expanding 

its CVD plant park with a new coating plant 

equipped with its own innovations. Boehlerit 

uses its expertise in coating technology and 

thus has the entire process in its own hands. 

This is one of the reasons for the company’s 

technological lead and offers new possibilities 

with regard to the deposition of innovative 

hard material coatings. 

One of the world’s most modern 4.0 RAM 

extruders, a new double-sided fine grinding 

machine with planetary kinematics, new 

clean ing and washing systems and new simula 

tion software, which, for example, examines 

chip formation and chip flow even before the 

step into the cutting laboratory, finalize the 

investment programme. All the new systems 

are networked with each other. Sustainability 

and energy efficiency have long been at the top 

of Boehlerit’s agenda of course. Especially in 

times of energy crisis, these investments are 

particularly effective in many respects. 

Boehlerit – the independent development partner for toolmaker 

tools with which complex indexable inserts are precision-manufactured. 

“Our hand shaping department requires very special know-how, and we use 

it to produce more than 7,000 different types of carbide parts every year”, 

Kolbeck adds. Here the constructive shaping, taking into account the socalled 

sintering shrinkage, requires a great deal of experience. In addition to 

sintering, Boehlerit’s know-how is based on its own coating center. The main 

coating technologies (PVD, HT-CVD and MT-CVD) for hard material coating 

of indexable inserts are available. 

State-of-the-art production machines guarantee 

the highest quality 

As part of its quality and automation offensive, Boehlerit has decided on a 

comprehensive investment package that specifically addresses the three decisive 

factors of its products – substrate, cutting edge finishing and coating. Four 

new high-end sintering systems (three pressure sintering systems and one 

vacuum sintering system) were purchased, as well as a large 5-axis turning/ 

milling machine on which preforms are produced. In addition six new grinding 

machines for inserts ensure a long-term guarantee of the high quality 

level. Boehlerit produces around 150 to 200 pressing tools made of sintered 

carbides per year for customers, but also for its own needs. For this purpose 

From powder to rapid prototyping 

to cutting tests 

The development tasks of the carbide pioneers 

at Boehlerit are defined respectively by the 

performance requirements of the tool manufacturers 

and users. Process-optimised manufacturing 

technologies, from its own powder 

production, coupled with the latest pressing 

and grinding technologies to the most modern 

coating technologies, guarantee toolmakers 

a head start in the productivity of their 

tools time and time again. A particular advantage 

in product development for toolmakers 

is the production of prototypes using 

state-of-the-art laser-assisted rapid prototyping. 

Boehlerit thus helps customers to save 

time and money in tool development. This 

also includes cutting tests, evaluation and 

advice. Finally one of the most modern testing 

and packaging systems for indexable inserts 

in the industry contributes to the high quality 

standard. It guarantees 100 % quality assurance 

in the μm range. With particularly strict 

dimensional checks and the monitoring of all 

metallurgical parameters, Boehlerit guarantees 

toolmaker a consistently high quality of 

its tools. 

further information: www.boehlerit.com 


19


A premium solution 

for hot mill roll grinding 

Designed with the increasingly competitive steel 

market landscape, 3M introduces its new premium roll 

grinding solution: a wheel that cuts faster, lasts longer, 

runs cooler and achieves substantial cost savings and 

productivity improvements. 

The 3M solution was built to meet the extreme challenges of 

narrow and tighter profile tolerances along with finer surface 

roughness expectations. Moreover, the total absence of defects 

such as feedlines or scratches require adapted grinding 

solutions. Compared to conventional wheels, 3M Cubitron II 

resin bond grinding wheels 92BC can complete up to 30 % 

more rolls. Longer-lasting performance is combined with up 

to a 20 % faster cut and 30 % lower cycle time than standard 

grinding wheels. 

Grinding wheels 92BC 

built to meet the 

extreme challenges of 

narrow and tighter profile 

tolerances along with 

finer surface roughness 

expectations 

3M considered several key market trends when designing 

its new grinding wheel such as process optimization, process 

efficiency, harder materials to grind as well as the increasingly 

more demanding quality standards required. Increasing 

grinding wheels’ durability and overall grinding performances 

is how the new 3M Cubitron II resin bond grinding 

wheels 92BC helps to achieve the industry’s costs savings targets. 

The new grinding wheels, additionally, free up capacity 

while helping to reduce overall grinding times. 

The most suitable grinding wheel specification will depend 

on the composition of the rolls. The content of chromium and 

other alloying elements is an important factor when selecting 

a grinding wheel’s specification. Generally the carbide-forming 

elements which generate these hard carbides in high alloyed 

steels, contribute strongly to how hard the specific steel 

grade is to grind. The harder the steel, the better the new 3M 

Cubitron II resin bond grinding wheel 92BC outperforms 

other conventional solutions. 

100 µm 

3M precision-shaped 

grains made with 

3M micro-replication 

technology enabling 

a more efficient 

grinding solution 

3M precision-shaped grains 

Conventional grains tend to grind through the metal causing 

heat to build up in the workpiece and the abrasive, resulting 

in a slower cut with a shorter lifetime. Whereas the unique 

3M precision-shaped grains made with 3M micro-replication 

technology, continuously form sharp peaks that easily slice 

through metal, thus cutting cooler, faster and lasting longer 

than conventional grains. 3M precision-shaped grains can 

now be oriented into a specific direction, thereby optimizing 

the usage of each single oriented grain. With the new 3M 

Cubitron II resin bond grinding wheels 92BC, 3M observed 

that grains stacking into a specific zone is far reduced thus 

preventing mineral agglomeration and notably reach better 

grains anchorage into the bonding system. 

New resin bond formulation with homogeneous pores forming 

and distribution drastically improves the overall cooling system 

resulting in substantial positive impact on performance 

New resin bond formulation 

Having a more homogenously distributed pore structure 

helps to drastically improve the overall cooling system since 

the entire wheel’s thickness is instantly flooded by the cooling 

fluid being captured by the wheel’s opened structure. Even 

in extreme stock removal conditions, it does facilitate chips 

evacuation outside of the contact area preventing from generating 

heat which may lead to thermal damages. The grinding 

process runs cooler with substantial positive impact such as 

wheel’s durability extension and work parts quality improvements 

(free of burning marks). Finest surface roughness (Ra): 

down to 0.3 - 0.5 µm is easily achieved and maintained. 

further information: www.3M.com 



Four inserts for stator bores 

Actuating tools are the means of choice for creating turning 

geometries on machining centers. When it comes to machining 

stator bores on electric motors, tools with indexable inserts and fine 

boring tools were considered the state of the art until now. MAPAL 

has developed a complex four-bladed actuating tool to round off 

its solution portfolio for stator drilling. 

With its Expert Solution, MAPAL has come up with a highly productive 

machining process for the series production of stator housings for electric 

motors. The solution offers productivity and precision as well as short 

cycle times with a process of three steps: pre-machining, semi-finishing and 

fine machining at machining diameters of more than 220 mm and with an 

HSK100 connection. A sophisticated actuating tool is part of the solution. 

“With an actuating tool the internal machining of the bore can be handled 

by a machining center, which means turning is no longer necessary”, says 

Oliver Müller, customer service specialist at the MAPAL Centre of Competence 

for Actuating Tools. The entire machining process can thus be executed 

with a single clamping setup. The only thing needed to use the actuating tool 

is a spindle with a drawbar – a so-called U-axis in the machining center. 

“When it came to machining parts for electric cars we were at our customers’ 

side with our tools from the very beginning. Today we help them to 

increase flexibility while machining the parts reliably and with short cycle 

times”, Müller explains. The actuating tool achieves more flexibility by 

ensuring both fast machining of varying contour trains in the bore as well 

as precision down to the micrometer. 

For example a thin-walled stator housing with a 220 mm stator bore is machined 

on a machining center with an HSK100 connection. “The machining 

of the stator bore with indexable insert tools and fine boring tools represents 

the state of the art. They have proven themselves over and over again. 

However, to achieve more flexibility for faster machining, we developed a 

tool with four slides together with machine manufacturers and customers”, 

Müller says. The drawbar controls four facing slides equipped with ISO 

inserts and handles both pre-machining and fine machining. PCD cutting 

edges are used as the housing is made of aluminium. After the machining 

is done, the inserts are retracted, and the tool is moved out of the housing 

via rapid traverse. This saves cycle time without the risk of damage to the 

new surface. This solution is particularly productive and focusses on high 

quality, which is why it has found its way into the Expert Solution range of 

MAPAL’s solution portfolio. 

Each of the four slides of the 22.5 kg heavy tool has a face stroke of 

20 mm – the inserts can thus be extended to 0 40 mm. The drawbar compensates 

for wear and tear directly during machining. This makes for particularly 

reliable machining. For even shorter cycle times, the actuating tool is designed 

as a combination tool. In addition to machining the stator bore, steel 

bushings are pre-machined with four carbide inserts. 

“The tolerance of the large bores is set to IT6 quality. That shows the precision 

with which our tools are manufactured, assembled and set. The four inserts 

have to interact with micrometer precision”, Müller states. 

The actuating tool with 

four cutting edges stands for 

high process reliability and flexibility 

during the machining of stator bores 

And so the experienced workers at the 

MAPAL Centre of Competence know the actuating 

tool inside out. Müller explains: “Assembling 

this sophisticated tool is similar to 

watchmaking.” It takes two to four weeks to 

assemble one tool. In order to set up the tool 

precisely at the customers’ premises, MAPAL 

offers a suitable setting device. The special 

machine is based on the UNISET-V and 

equipped with an additional axis – like the 

machining center. 

Cutting data: 

▶ aluminium machining 

v c = 690 m/min 

f z = 0.20 mm (pre-machining) 

f z = 0.15 mm (fine machining) 

spindle speed = 1000 rpm 

▶ steel machining 

v c = 160 m/min 

f z = 0.16 mm 

spindle speed = 690 rpm 

Not only the cutting data (see box) and the 

resulting surfaces with an Rz < 6.3 µm convince 

on the shop floor, the tool life of the inserts 

also does. The PCD inserts can machine 

3,600 parts before being changed. The carbide 

inserts manage 600 parts. “Our customers are 

very happy with the tools”, Müller relates. 

“The housings continue to be further developed; 

the contours slightly adapted. Thanks to 

the actuating tool, we can react to this easily 

and without changing the tool.” 

further information: www.mapal.com 


21

news & facts 

Fiscal year 2022 – 

Fritz Studer AG 

At this year’s press conference of Fritz Studer AG, CEO 

Jens Bleher welcomes the press representatives to a historic 

site: “Exactly 111 years ago Fritz Studer founded 

his company here in Steffisburg. Since then the pioneer 

in cylindrical grinding has presented countless technological 

innovations – a long tradition that is our obligation 

for the future.” 

We are therefore particularly pleased that STUDER succeeded 

in continuing its growth course in 2022 and significantly increase 

sales. Bleher is thus also very positive about the outlook 

for 2023: “After a remarkable final spurt at the end of the 

year, STUDER started 2023 in full momentum, with a large 

order backlog.” 

Positive development of the order situation 

“Overall it was the third-best year in our company history in 

order intake,” says CSO Sandro Bottazzo. Expectations were 

exceeded by far in all sales regions. Some countries, such as 

Turkey, even recorded the highest order intake in company 

history. As a global manufacturer of high-precision grinding 

machines, STUDER is worldwide active. “All in all, in 

2022 we once again succeeded in expanding our position in 

the most important markets in the world and increasing our 

market share,” summarized Bottazzo. 

In 2022 almost all markets showed growth in orders. New 

customers made 37 % of the orders. Furthermore, the secondbest 

individual month in the history was December. The aerospace 

and energy segments contributed to this positive development 

significantly. The tooling, die and mold, and machine 

manufacturing segments remained stable at a very high 

level. The precision engineering segment with the small and 

medium-sized supplier companies and contract manufacturers 

remains the largest individual segment. In the automotive 

sector on the other hand was a decline, which specifically 

affected demand for production machines. “However, our 

good positioning and broad portfolio are helping us greatly,” 

emphasizes Bottazzo. 

Broad portfolio as key to success 

A broad portfolio that can fulfill a wide variety of customer 

requirements is both our trademark and an important pillar 

for STUDER’s success. In the 2022 business year universal 

and internal cylindrical grinding machines showed a positive 

trend, in both the standard and system business. The bestseller 

among the STUDER machines was once again the versatile 

S33 CNC universal cylindrical grinding machine, which 

is capable of producing small and large workpieces in both 

single and series production. Other machines that sold very 

well were the favorit, the S31 and the S41. In the sales of internal 

cylindrical grinding machines, STUDER achieved its 

second-best annual result ever. Another area that reached a 

record high was the WireDress® technology, which enables 

the precise dressing of metal-bonded grinding wheels possible 

and thus boosts productivity to extremely high levels. 

Stephan Stoll - COO, Jens Bleher - CEO, Sandro Bottazzo - CSO 

and Daniel Huber - CTO (beginning left) 

Customer care with record sales 

Bottazzo has more good news from the area of customer 

care. Here STUDER achieved a new revenue record in 2022. 

STUDER has further expanded its service organization because 

of good business developments. Customers profit from 

even better availability and faster problem-solving, numerous 

business processes have been digitized and optimized. 

Development of numerous new products 

The 2022 business year also brought numerous new developments 

and an expanded product range. “With our product offensive, 

innovative and application-specific solutions, we can 

even better address the needs of our customers,” says Daniel 

Huber, CTO at STUDER. On the China market, on the one 

hand, the new generation of the well-proven KC33 CNC universal 

cylindrical grinding machine was presented. On the 

other hand Chinese customers now have, with the ecoGrinder, 

an economical entry-level solution available – and it has already 

found numerous buyers. “In 2022 we presented an innovation 

at almost every large trade show,” says Huber. This 

includes the S36 production machine at GrindingHub in 

Stuttgart. It closes a gap in the portfolio between the S11 and 

S22 and is particularly well-suited to applications and components 

in the field of electromobility. Now the S36 is also 

available with an innovative energy monitoring concept. Or 

there’s the new S100 that was presented at the BIMU in Milan, 

a perfect entry-level option in the field of CNC universal internal 

cylindrical grinding machines. 

Investment in the future 

Regular and systematic investments in all areas of the company 

are part of STUDER’s company philosophy. “We are 

con vinced that this will keep our locations competitive and 

that Studer machines ‘Made in Switzerland’ will have a strong 

foothold on the world market in the long term,” explains Stoll. 

Following the redesign and modernization of assembly, the 

focus was on manufacturing over the past few years. In 2022 

several projects contributed to ensuring that the production 

resources remain state-of-the-art, with a special focus on 

automation and digitization. In the coming year spindle shaft 

production will be renewed and expanded, and the warehouse 

and logistics infrastructure comprehensively modernized 

by 2025. 

further information: www.studer.com 


news & facts 

New location in Thailand 

From April 2023, the Horn Group will have a subsidiary 

in Thailand. Horn Cutting Tools (Thailand) Co. 

Ltd. will have its headquarters in Chonburi – approximately 

80 km (49.7 miles) south-east of Bangkok, the 

capital of the Kingdom of Thailand. 

The company will commence operations with six employees. 

In the short to medium term, a regrinding service for MCD 

tools will be set up in addition to the sales department. 

Horn Thailand will be exhibiting at Metalex in Bangkok, 

November 22 nd – 25 th , 2023. On display will be Horn’s 2023 

innovations and various tooling solutions such as Supermini, 

gear cutting, reaming and grooving. 2022 more than 86,000 

trade fair visitors came to Metalex. In addition to domestic 

visitors, people came primarily from India and Singapore. 

Concerning trends and future issues in Thailand, Andreas 

Vollmer, member of the management board at HORN and 

responsible for worldwide sales said: “What we have seen so 

far and the discussions we had during the Metalex exhibition 

in Bangkok last year show that machining strategies are 

identical to existing customer requirements that we are already 

familiar with, not only in Thailand but also in Vietnam 

Singapore, Indonesia, Malaysia and the Philippines. The topic 

of gear cutting is already a live discussion.” 

The Horn Thailand Team is very well prepared for the tasks 

ahead. Technical product training will take place in the new 

offices in order to pass on a high level of technical expertise to 

customers. Horn Thailand will also have a warehouse on-site 

to serve the Southeast Asian market to ensure quicker and 

safer deliveries. 


The Horn Thailand team: Uten Tonsirach/production, 

Michael Mellerup/general manager, 

Jakapat Udomporn/national sales manager (beginning left) 

The company headquarters of 

Horn Cutting Tools (Thailand) Co. Ltd. in Chonburi 

with a total area of approx. 1,250 m 2 

New representation in Denmark 

MAPAL extends the long-standing partnership with Edeco Tool 

Since February 1, 2023, Edeco Tool ApS has been the 

official sales representation of MAPAL in Denmark. 

The company is already a long-standing partner and 

has been working successfully with various centers of 

competence of the MAPAL Group. 

Due to these good relationships the management of MAPAL 

decided to give Edeco Tool ApS the official representation for 

Denmark. 

Armin Kasper, vice president sales: “We are pleased to 

have found a well-established partner with Edeco Tool ApS. 

Due to its organisational structure as well as its technically 

experienced staff, we can ensure the best possible support 

for our customers in Denmark. We are confident that this 

change will be well received by the market.” 

The team in Denmark knows MAPAL’s range of products 

and services. They are specialists who understand the customers’ 

requirements and bring considerable experience to 

the extended cooperation. Edeco is active in various areas of 

industry. The company serves customers in the automotive 

and mechanical engineering sectors, as well as die and mould 

making, the energy sector and the aerospace industry. 

The trading company, which serves customers in Denmark 

and Sweden, operates a central warehouse in Swedish Karlstad. 

This ensures that also the customers in Denmark receive 

standard products quickly and reliably. Edeco Tool ApS is 

based in Glostrup near Copenhagen, a regional office is also 

located in Thisted and serves customers from Jutland. A wide 

range of MAPAL tools is available at the Edeco Webshop. 

further information: www.mapal.com 


23

news & facts 

Vollmer appoint new UK managing director 

VOLLMER has now appointed Martyn Cross as the new managing 

director of the VOLLMER UK subsidiary. Working alongside longstanding 

managing director Peter Allen in the interim, Martyn has 

joined VOLLMER UK to build upon the strong growth already overseen 

by Peter Allen over the last 24 years. 

Since the end of 2012 Peter Allen has filled two roles as both managing director 

of VOLLMER UK and president of VOLLMER of America. With the 

recent construction of a new facility at VOLLMER of America and the high 

demand for technologically advanced solutions in the UK as well as the USA, 

Canada and Mexico, Peter has decided to fully focus on the exceptional potential 

of the North American marketplace. With Martyn Cross joining the 

VOLLMER UK team, the company will have a dedicated managing director 

with decades of expertise in the cutting tool manufacturing sector. 

Martyn served a mechanical apprenticeship in the 1970’s and has progressed 

his career from apprentice to applications engineer, on to positions as 

technical sales manager, production manager and subsequently director with 

many of the world’s leading tool and cutter grinding machine tool manu - 

facturers. Such is the expertise of Martyn; he has also spent time working as 

an R&D manager at a prominent UK cutting tool manufacturer. 

Upon Martyn’s appointment, joint managing director at VOLLMER UK, 

Peter Allen says: “We are delighted to appoint an engineer, manager and 

leader of Martyn’s caliber. Martyn’s industry knowledge, insights and reputation 

precede him. The experience that Martyn will bring to VOLLMER UK 

is second to none and his unfathomable relationships within the industry 

will certainly help to further enhance the position of VOLLMER in the UK.” 

“The VOLLMER brand is growing exponentially with the launch of a completely 

new suite of machine tools launched at GrindingHub last year. Not 

only is VOLLMER a full-line manufacturer of grinding, erosion and laser 

machine tools with a growing portfolio, but we have also introduced new 

brands and technologies to the group such as the ultraTEC ultrasonic deburring 

systems. To attentively support our customers in the UK and North 

America with the growing range of machine solutions, I have made the conscious 

decision after a lot of hard commitment to both subsidiaries, to gradually 

step away from the UK business and focus on the next chapter of my 

career with VOLLMER of America.” 

Peter Allen (left) hands over his position 

as managing director of Vollmer UK to 

Martyn Cross 

“After serving as the UK managing director 

for more than 18 years there will be a transition 

period where I will be introducing Martyn 

to our internal and external teams, our company 

structures and to many of our prestigious 

UK customers. I have little doubt 

that Martyn will build upon the growth the 

VOLLMER UK team is delivering and drive 

the company forward.” 

further information: www.vollmer-group.com 

GEFERTEC now wholly owned by the 

Berlin.Industrial.Group 

Effective immediately, B.I.G. Holding is the sole owner of 

GEFERTEC. In a joint decision with founding partners Tobias 

Röhrich and Georg Fischer, the Group has acquired their shares. 

B.I.G. Holding had already purchased the shares of EMAG (10 %) in 

June last year. 

“This gives GEFERTEC the necessary freedom of action to further expand 

and solidify its position in the growing market for 3D metal printing,” says 

Igor Haschke, managing director of GEFERTEC and owner of the Berlin.Industrial.Group. 

(B.I.G.). 

Demand for these machines is rising, particularly in the USA. GEFERTEC 

offers complete manufacturing systems for metal 3D printing in the 

Wire-Arc-Additive-Manufacturing (WAAM) 

process. Therefore the traditional gas metal 

arc welding is combined with special process 

expertise for the additive manufacturing 

of components, a robust machine system, integrative 

CAM software and process-related 

quality assurance. The robust process, high 

build rates and ease of handling wire as a 

feed stock make the process interesting for 

manufacturing medium to large components. 

further information: www.gefertec.de 


fairs 

news & facts 

EMO Hannover 2023 focuses on current production technologies 

Joint booths keep production experts up to date 

Want to learn about the latest in production technology? 

Production experts to EMO Hannover 2023 

will be doing just this in September. They can experience 

live and on site the latest trends at a total of four 

joint booths. These booths will be focusing on additive 

manufacturing, connectivity, open space cobot solutions 

and sustainability. 

Martin Göbel, director exhibitions at the EMO organizer 

VDW (Verein Deutscher Werkzeugmaschinenfabriken, or 

German Machine Tool Builders’ Association) in Frankfurt am 

Main, knows the value of a visit: “Nowhere else can production 

specialists experience the sector’s innovations so close 

up – presented in thematic packages over the entire process 

chain, and up to date at all times. So if you’re coming to EMO 

Hannover 2023 in September, you shouldn’t miss out on the 

joint booths.” 

Innovative 3D printing as a fixed constituent 

No matter whether aircraft construction, medical engineering, 

or hydrogen economy – additive manufacturing methods 

are growing in importance in production. And the business 

prospects are good: this was verified recently by a survey 

among the approx. 200 member companies of the Additive 

Manufacturing Working Group within the VDMA (Verband 

Deutscher Maschinen- und Anlagenbau, or German Engineering 

Federation). Almost three quarters of these companies are 

expecting in the coming 24 months an upward trend in their 

business in Germany. Yet the technology can only utilize 

its full potential when it is integrated successfully in highly 

automated industrial process chains. 

How this works is demonstrated in the Additive Manufacturing 

Area. Here companies will be presenting pioneering 

concepts from the whole bandwidth of the additive process 

chain, whether direct and indirect 3D printing technologies, 

engineering materials, or rapid product development (RPD). 

Connectivity of production processes at a glance 

In digital production machines must be able to communicate 

with each other, irrespectively of their make, age, or controller. 

The Future of Connectivity Area therefore focuses on 

these processes. Here visitors will encounter new applications, 

automation processes, smart production, Industry 4.0, 

machine learning, predictive maintenance, IIoT (Industrial 

Internet of Things), and many other aspects. And the editorial 

series Future of Connectivity will also be reporting on 

these subjects in the run-up to EMO Hannover. 

Humans and robots work hand in hand 

More and more companies are investing heavily in automation 

to maintain their productivity and competitive strength, 

to augment their resilience and versatility, and to keep pace 

with growing demands. For instance the number of new 

industrial robots installed in 2021 exceeded the 500,000 mark 

for the first time – a new record. Specifically cobots, or collaborative 

robots, are in high demand. They already now make 

up 7.5 % of all installed industrial robots, and this is an upward 

trend. 

The Open Space Cobot Solutions Area is therefore fully 

dedicated to the interactions between humans and industrial 

robots and their actual and potential applications. Manufacturers 

will be presenting to an international trade public 

their automation solutions based on cobots and their innovative 

use: grippers, image processing, measuring systems, 

software, industrial electronics, feed systems, and much more 

can be experienced up closely. 

Sustainability to underlie tomorrow’s production 

The declared goal of the 2015 Paris agreement is to limit the 

rise in mean global temperature to a maximum of 2° C. At the 

latest since then it has become clear: the subject of sustainability 

is seen as a challenge of global import affecting society 

as a whole. Among other intentions, the European Union 

has resolved as a result to render its economy and society carbon-neutral 

by 2050. The manufacturing industry too is feeling 

the considerable effects, and it sees itself faced with equally 

imposing challenges – and opportunities. 

At EMO Hannover 2023, the Future of Sustainability in 

Production Area provides the ideal environment for experiencing 

the latest solutions for tomorrow’s production. Here 

visitors can learn about the current trends in energy efficiency, 

the integration of renewable energies, circular economy, 

and lifecycle concepts – a fair highlight, not only with 

an eye to climate protection and reduced production costs in 

times of persistently scarce energy and raw materials. 

further information: www.emo-hannover.de 


25

news & facts 

fairs 

parts2clean 2023 

Industrial parts cleaning redefined 

As a result of structural changes in industry, plus 

several new megatrends and the energy transition 

itself, the tasks and requirements in industrial parts 

and surface cleaning are also in a perpetual state of 

change. 

The 20 th parts2clean takes this development into 

account with an expanded range of solutions and a 

new highlight topic: “High purity”. This anniversary 

edition of the leading international trade fair for industrial 

parts and surface cleaning will take place 

September 26 to 28, 2023, at the Stuttgart exhibition 

grounds. 

As the leading international networking hub for industrial 

parts and surface cleaning, parts2clean reflects the requirements 

of a number of user industries and offers a globally 

unique portfolio of solutions. This will become even clearer 

at this year’s anniversary event, thanks to an expanded 

range of offerings and the event’s new claim titled “Cleaning 

redefined”. 

In the words of Hendrik Engelking, global director at 

Deutsche Messe: “In addition to the familiar core areas of 

industrial parts cleaning, we are thus also covering new and 

ever-changing tasks that arise – for example from the mobility 

and energy turnaround, the trends of automation, digi - 

tization and AI, sustainability, and, in some industries, 

stricter regulatory requirements. For example cleaning solutions 

for electronics manufacturing, e-mobility, sensor technology, 

optical industry, medical and pharmaceutical technology 

will play a greater role,” he adds. And the energy efficiency 

of cleaning systems and processes is another area to 

be covered by the upcoming parts2clean. 

High purity – 

more than just cleaning 

For the first time in parts2clean’s twenty-year history, this 

year’s edition will feature a highlight topic, “High purity”. 

“The focus here will be on tasks that need to be solved, 

among other things, for complex mechanical components for 

the semiconductor supplier industry, in the precision optics 

and optoelectronics industry, thin-film technology, medical 

technology, as well as vacuum-technology components for 

the UHV, XHV and UCV sectors,” reports Engelking. 

The extremely stringent specifications for ultra-fine particulate, 

film-chemical, organic and inorganic purity required 

in these areas can only be met if the entire process 

chain is taken into consideration. Of course, the cleaning 

system also plays an important role here, but factors such 

as the cleanliness of the pre-processes, production materials 

and media, handling influences and ambient conditions, 

for example an adapted cleanroom, are just as decisive for 

stable, achievable results. It is also important to avoid recontamination 

and cross-contamination. 

Future-proof solutions for 

current and future requirements 

“With its expanded range of solutions, as well as the highlight 

topic of high purity, parts2clean continues to gain in 

attractiveness as the world’s most important tradeshow for 

industrial parts and surface cleaning,” reports Engelking. 

And this is also the case in industrial sectors that may not 

have felt addressed in the past. This is because the cross-sector 

and cross-material offerings also enable companies to find 

out about cleaning applications and solutions in sectors of 

industry in which they have not previously been active. In 

addition users from all manufacturing sectors as well as from 

remanufacturing and recycling will find future-proof solutions 

to meet current and new require ments in a stable and 

efficient manner. 

Knowledge transfer included – 

bilingual expert forum 

The bilingual expert forum will also make a valuable contribution. 

The simultaneously translated (German English) 

presentations by renowned speakers from science, research 

and industry will address current tasks and developments 

from a number of different business sectors. “parts2clean 

thus offers national and international visitors one of the most 

sought-after sources of knowledge for learning about trends, 

innovations, benchmark applications and reports from the 

field,” says Hendrik Engelking. The knowledge meeting 

point, which is organized jointly with the Fraunhofer-Business 

Area “Cleaning” and the German Industrial Parts Cleaning 

Association (FiT), is integrated into the flagship trade fair, 

and attendance is free of charge for visitors and exhibitors. 

further information: www.messe.de 


fairs 

news & facts 

The Champions League 

of the industry in one place 

Moulding Expo will highlight the importance and efficiency 

of the tool, pattern and mould making industry. 

Tools and moulds are required in every industry in order to 

be able to manufacture high-quality products in large unit 

numbers. It is therefore becoming increasingly more important 

to organise the production process in an even more 

efficient and cost-effective way, and also take account of 

integrated solutions. 

A key role in this respect is played by reliable and innovative 

tool construction partners with modern and highly 

automated production as well as corresponding experience 

and know-how. Leading tool, pattern and mould making 

com panies will demonstrate their expertise and offer solutions 

for different branches of industry at Moulding Expo 

June 13 – 16, 2023. 

“We are looking forward to welcoming around 400 exhibitors 

at Moulding Expo 2023. These exhibitors will include 

the champions league of the tool, pattern and mould making 

industry along with relevant technology suppliers. Product 

developers, tool buyers, plastics processors and operators 

of an internal or external tool, pattern and mould making 

facility should plan a visit to Moulding Expo,” said Florian 

Niethammer, head of Trade Fairs & Events at Messe Stuttgart. 

Under one roof at Moulding Expo the exhibitors will present 

customised solutions for different industries – for example 

the automobile industry, the aerospace industry, the electrical 

engineering industry, medical technology, mechanical 

engineering and the photovoltaic industry. 

The international trade fair is divided into several exhibition 

areas. The focal point of Moulding Expo is the tool, pattern 

and mould making industry which is very user-oriented 

with its injection moulding tools, die-cast moulds and forming 

tools, as well as gauge construction and jig and fixtures 

manufacturing. The trade fair will also feature systems and 

services relating to plastics technology and metal working: 

from suppliers of machine tools, clamping devices, machining 

tools and measuring systems, and suppliers of materials, 

standard components and hot runner systems through to 

software companies. 

further information: www.messe-stuttgart.de 

Fourth annual Open House & Technology Days 

Ready to take efficiency in manufacturing to the next 

level? ZOLLER’s fourth annual Open House & Technology 

Days event will take place May 9-11, 2023, at 

ZOLLER’s state-of-the-art North American headquarters 

in Ann Arbor, Michigan. More than 300 guests 

attended last year’s event and organizers expect this 

year’s program to attract even more attention. 

Over the span of three days participants can network and 

learn from the best in the industry, including ZOLLER 

experts, loyal customers and other industry leaders. They 

will discover the latest developments in tool presetting, tool 

inspection and tool management technology and how the 

entire process chain of ZOLLER Solutions can increase productivity 

and efficiency in a connected and scalable way. 

More than a dozen speakers are expected to present during 

the three-day event. ZOLLER president Alexander Zoller will 

provide the keynote address on his vision for success in smart 

manufacturing at shops of all sizes. Each day will also include 

tech talks, breakout sessions and live demos, including interactive 

demonstrations of the new ZOLLER tool balancing 

and heat shrinking solutions, toolholders and the “roboSet 2” 

24/7 tool inspection automation solution. 

The Open House & Technology Days event will also feature 

demos of the entire suite of ZOLLER solutions. Participants 

can learn how to implement the industry’s best tools to maximize 

efficiency and control over their tooling and production 

processes. 

further information: www.zoller.info 


27

news & facts 

LACH DIAMANT – 100 Years 

Tradition. Passion. Innovation 

part 5: 

The dawn of a new age of cutting technology – 

from a natural diamond cutting company 

to the pioneer of polycrystalline diamond 

and CBN tooling 

“When I held my first diamond in my hand in 1908, I would not 

have imagined that one day diamonds would not only be used in the 

automobile industry but also for the machining of wood and plastics”. 

Jakob Lach, the company founder, said this on camera in 1980. 

It would become the preface for the first presentation of a new technique 

for machining wood and plastics – using diamonds as cutting 

material – the Dia Tool. This video, with audio translated into 

multiple languages, has lost none of its relevance for the choice of 

appropriate tools within the furniture, flooring and composite industries; 

the video can be viewed at: https://bit.ly/LACHDIAMANT 

Company founder Jakob Lach, 1894-1984 

(photo taken in 1980) 

The year is 1973. 50 years ago. Energy crisis, 

marked by the first major oil crisis. Fuel prices 

were skyrocketing. The first automobile-free 

days. Highways were left to pedestrians and 

bikers. VW built its first water-cooled front 

engine and celebrated its premiere with the 

“Passat.” 

LACH DIAMANT, the diamond tool manu - 

facturer from Hanau (previously known as 

the city of fine jewellery) is in the midst of a 

eupho ric growth spurt. On top of a wave of 

success thanks to the newly developed CBN 

grinding wheels with Borazon® (CBN), an 

abrasive for grinding HSS and high-alloy 

hardened steel. 

During this exuberant euphoria, the “advertisers” 

at LACH DIAMANT were bold 

enough to publish a persiflage brochure, 

“warning” customers of Borazon®, on one of 

the tradeshows in Hanover 1970/71. The slogan 

“Do you want to play cards too?” was not 

always well-received. 

This development came at a price, the available 

space at the property at Bruchköbeler 

Landstr. 39 was bursting at all seams. This 

Polycrystalline diamonds (PCD), 

manufacturing process and division into 

solderable inserts – size as of 1973 – for the 

manufacturing of cutting tools (GE graphics); 

today PCD blanks are available up to 0 70 mm 


news & facts 

Borazon® advertising “warning” all tool grinding shops of extended tooltimes, 

and that their employees will have time to play cards due to shortened grinding times 

with Borazon® – “Do you also want to play cards?” 

was true for both manufacturing and administration. All capacities 

for setting up new automoulders or expanding the 

turning shop were exhausted. The development of the fallow 

property no. 41 promised relief. A double- storey factory 

building for the production of resin and metal bond diamond 

and Borazon® (CBN) grinding wheels, including a turning 

shop was constructed on the site. A four-storey office building 

was built as well. The entire complex was finished 1972. 

For the first time, during the expansion of both diversification 

of business and product portfolio, things had calmed 

down… if there had not been an increasing persistent rumour, 

end of 1972/beginning 1973, about a new synthetic cutting 

material, developed by US-manufacturer General Electric. The 

available, scattered information did not allow any conclusion 

about which type of cutting material came in question. Fact 

was that the company “Carboloy”, a GE-affiliate, kept compact 

boron nitrite inserts (turning inserts) in stock since approximately 

1970, so I guessed it to be a Borazon® cutting material 

(at this point, Carboloy probably had no interest in a 

cutting material superior to carbide, and rather sold carbide). 

Another cutting material, for example based on “diamond”, 

would not be under consideration according to my thoughts 

at that time. How could it be? Compared to “diamond”, a 

cutting material containing Borazon®/CBN would have the 

best sales prospects and the best chance in the hardened steel 

machining industry. 

Rumours about a new cutting material 

With natural diamonds at our disposal, and with the 

LACH DIAMANT cutting shop, we were best suited for our 

production of natural diamond turning steel and for turning 

of copper commutators for customers like Bosch, Siemens, 

AEG etc. 

We received note of this new cutting material end of 

March/beginning of April 1973, just in time to introduce it at 

the coming Hanover spring tradeshow in April. 

In order to invite potential major customers to this tradeshow, 

my research led me to a ferrous material named “Ferro 

Titanit” by DEW, the German Ferrous Material Factory in 


29

news & facts 

Krefeld. My acquisition efforts and the announcement 

of a coming new “CBN compact” 

material was immediately met with spontaneous 

approval from the DEW board of directors. 

A few days later, two members of the 

board sat in my father’s parlour and listened 

to my presentation; my explanations were 

mainly justified by my knowledge of the machining 

of high-alloy steel with Borazon®/ 

CBN grinding wheels. 

You, my dear reader, will forgive me this 

(premature) gaffe, the gentlemen from DEW 

however did not and later were disappointed. 

The surprise came only a few days later. It was 

not a compact Borazon®/CBN cutting material, 

as I had speculated, but it was “diamond.” To 

be more exact: polycrystalline synthetic diamond, 

by now commonly known under its acronym 

“PCD”. 

The first PCD inserts came as 90 ° and 60 ° 

segments, cut out of a blank with a diameter 

of “only” 3.2 mm. The visible PCD diamond 

layer of approx. 0.3 to 0.4 mm was joined to a 

carbide metal holder, with the effect that the 

cutting edge could be further processed by 

brazing. 

Initial grinding tests 

It was Friday, exactly three work days before 

the opening day of the tradeshow April 26 th , 

1973. Proudly I presented the first PCD to 

Kurt Wagner, head of our natural diamond 

cutting shop, and an exceptionally gifted diamond 

cutter who had top-notch experience 

from his employment as a diamond specialist 

at a Swiss manufacturer of turning tools for 

jewellery and watches. After a thorough exam - 

ination and grinding tests on a diamond dust 

coated, cast grinding wheel (obviously meant 

for natural diamonds), he explained to me: 

“Boss, we usually do everything you ask for, 

but this stuff is so beastly and isn’t naturally 

grown, there is nothing we can do!” Great, I 

thought, probably that was it. What now? We 

did not have the luxury of many more grinding 

options at that time. But then I remembered 

our Simon steel grinding machine 

(L15). This machine had been purchased during 

our cooperation with the company Simon, 

Neu-Isenburg, a distributor of resin and metal 

bond diamond wheels. I remember to this 

day saying to myself: “Then let’s try it on the 

Simon machine with a cup wheel!” 

And sure enough, the first grinding test 

with the resin bond diamond grinding wheel 

was already promising. However it still was an 

effort of several hours in order to achieve the 

desired geometry of the cutting edge. 

Grinding of a polycrystalline turning steel on a Simon steel grinding machine 

This stuff lasts so long… 

Right on time for the tradeshow start at 9 a.m., our driver Mr. Barmus delivered 

the first PCD tool to our booth at the fair. It would henceforth bear 

the registered name “dreborid®”. Wednesday and Thursday the driver came 

again with yet another turning tool, until we explained to him: “This stuff 

lasts so long” that he would not have to bring any more tools. 

By the way, technically speaking “the stuff lasts so long” is equivalent to 

“tool life.” We did not make any statements in this regard at the Hanover 

tradeshow – how could we – after just a few hours experience during the 

turning of an aluminium part. The part contained bore holes in different 

sizes in order to simulate interrupted cuts. 

Presentation of the first dreborid turning steel with simulated, interrupted cut 

during the machining of aluminum at the Hanover spring tradeshow in 1973 


news & facts 

Cautiously one or the other LACH DIAMANT 

technician answered respective questions, 

estimating a tool life 10-20 times longer than 

compared with a carbide blade, and naturally 

even greater compared to an HSS turning tool. 

Today we know that compared to all abrasive 

materials, such as SiC containing aluminium, 

bronze, fiber-glass (GRP) and carbon fiber 

(CFRP) containing materials, ceramic components, 

all wood materials/composites, the 

durability is more than two to three hundred 

times as long. I deliberately mention “copper” 

last. For the second time in the company’s 

history, “copper” opened the door to further 

economic growth. 

Once again the copper commutators which 

are necessary for the perfect functioning of 

electric motors played an important role. In 

the 1960’s, 20-30 cutters of natural diamonds 

helped to replace carbide turning tools with 

diamond tipped tools. With such natural 

diamonds it was possible to turn 30 commutators, 

and in one case up to 120,000 pieces 

perfectly. Companies like Bosch, Siemens 

and AEG profited from tools made by LACH 

DIAMANT, and especially from our regrinding 

service. 

Engineer Karl Krügel’s (†) demonstration of application was received with 

astonishment and, in most cases, with enthusiasm by tradeshow visitors 

Expanding the customer base 

However both we and our customers had to 

accept that tool life was still rather inconsistent. 

When the cutters were asked they just 

shrugged their shoulders and answered: “It’s 

natural diamond, naturally grown, unique 

and different, just like humans.” We were fully 

aware of this fact when we brainstormed 

potential applications and potential customers 

for this compact polycrystalline diamond 

composite. 

PCD gave us the chance to expand our customer 

base, including other manufacturers 

of copper commutators. Our cutting shop for 

natural diamonds was at full capacity. 

When doing my research one company 

caught my interest, one that was apparently 

also involved in the production of commutators. 

Our first conversation however was not 

encouraging. They manufactured “raw commutators”, 

delivered them to our current customers, 

not turned but ground. 

To Kautt & Bux this seemed an interesting 

thought. Turning instead of grinding? This 

would save a lot of time. We agreed to meet 

at the tradeshow. Unlike with DEW (machining 

FerroTitanit) it was a success. Still at the 

tradeshow, we received the first order for ten 

dreborid® PCD turning tools. 

First information on dreborid® PCD cutting inserts, 

published for the Hanover tradeshow in April 1973 


31

news & facts 

A win-win situation for LACH DIAMANT 

and all of our customers. Our first major customer, 

Kautt & Bux, could boast to be the 

first company in the world to use polycrystalline 

diamonds in serial production. The entire 

manufacturing process was converted to 

turning the copper commutators. 

A walk with consequences 

Now let’s take a look back at the production 

situation at the company premises at Bruchköbeler 

Landstrasse. The production of resin 

and metal bond diamond Borazon® CBN 

grind ing wheels as well as the production of 

single diamonds and polished profile and 

copy diamonds were booming. Space for new 

installations of now necessary tool grinding 

machines for the production and grinding 

of PCD tools was limited, not to mention 

the installation of a separate production section. 

That was the situation then, although the 

company had just completed a large building 

extension project. 

Turning of a copper commutator with one of the first 

newly-manufactured dreborid® PCD tools 

Out of the blue Jakob Lach, already 79 

years of age, made a suggestion. On one of 

his walks, not too far from us, approximately 

2 km away, he had discovered a promising 

property with a large building in the back – a 

former diamond sawmill. So we rented the 

property. With the result that our just previously 

installed wheel production, including 

all of the pressing machines, had to be moved 

and make room for our laboratory and turning 

shop. Manufacturing, construction and 

development of polycrystalline tools for 

copper, aluminium and composite machining 

was now done in our original building 

at Bruchköbeler Landstrasse, and we then 

were able to develop the knowhow that today 

distinguishes the LACH DIAMANT company 

as a technological pioneer. 

How things proceeded with “100 years 

of LACH DIAMANT”, will be revealed in 

the 6 th installment of this article series. It 

will contain exciting and so-far unpublished 

details regarding the first-ever presentation 

of new tool blades. 

Yours, Horst Lach 

further information: www.lach-diamant.de 

Are you enjoying this history of 

LACH DIAMANT? 

You can download part 1 - 4 

(from 1922 through 1972) for free at: 

https://bit.ly/anniversary-series 

The fast-growing dreborid® PCD programme for machining aluminium, 

copper, graphite and composite materials 


processes 

Sustainable process chains for the manufacture 

of resilient and smart tools 

Whether drilling, turning or milling: in machining – 

as well as in primary forming and re-forming, die casting 

and many other applications – tools are of pivotal 

importance for industrial production. Their performance 

significantly influences both the quality and the 

cost of the manufactured product and, consequently, 

the economic and ecological sustainability of the production 

process. One objective of the work at the 

Fraunhofer Institute for Surface Engineering and 

Thin Films IST in Braunschweig is the development of 

resilient and smart tools under the requirements of 

sustainability. 

The researchers thereby take the entire process chain into 

ac count – from tool design and material char ac ter i zation, 

through pre-treatment, cleaning, and customized surface 

treat ments and coatings, and on to testing and application. 

The key to the manufacture of resilient high-tech tools 

which retain their value-adding and economic operability 

under even the highest stresses is an optimized tool construction. 

This encompasses both the selection of the material 

and the design, thereby taking into account geometry and 

topography as well as the use of heat treatments and suitable 

coatings. At the Fraunhofer IST optimizations in the manufacturing 

process are therefore investigated throughout the 

entire process chain. The process begins with an analysis or 

characterization of the materials to be machined and an optimum 

design of the tool, which also includes the selection of 

a suitable coating. 

The actual production process for the tools begins with 

the manufacture of the basic body. Following pre-treatment, 

Tools coated with CVD diamond 

e.g. etching, sandblasting and cleaning, the focus is directed 

on the optimal design of the surface. Depending on the tool 

and its intended use this can, for example, be hardening by 

means of plasma diffusion treatment or a customized coating. 

In addition to access to a wide range of technologies 

and industrial equipment, the experts at the Fraunhofer IST 

can draw on many years of experience and user knowledge, 

enabling, for example, friction and wear properties to be 

specifically adjusted and tool life to be optimized. In order to 

exploit all efficiency potentials in terms of both energy and 

resource consumption, they combine the tribological functional 

coatings with thin-film sensor technology where necessary. 

Very thin sensor layers, directly in the main stress 

zones of the tools, enable the recording of relevant process 

data such as pressure, temperature or wear. These so-called 

smart tools therefore fulfil the prerequisites for the digitalization 

of processes and process chains and, furthermore, offer a 

diverse range of approaches for the optimization of production 

in terms of quality, safety, productivity and flexibility. 

The concluding step in the process chain is the testing and 

quality assurance of the tools. For the sustainability assessment 

of the various measures, development-related life-cycle 

analyses (LCA, LCC) are performed at the institute. 

The use of resilient and smart tools in conjunction with a 

digital process chain offers major potential for safe, efficient, 

flexible and sustainable production and can therefore provide 

a contribution towards increasing Germany’s competitiveness 

and securing its position as a production location. 

On the Fraunhofer joint stand in the “Production” section 

at Hannover Messe, the Fraunhofer IST demonstrated 

the potential of coating and surface technology for the manufacture 

of sustainable tools. Exhibits included cobalt-free 

carbides for machining, service-life-optimized tools with 

CVD diamond coating and smart and resilient tools for die 

casting and re-forming. 

Diecasting cores during plasma nitriding 

further information: www.ist.fraunhofer.de 


33

processes 

Additive-subtractive manufacturing of 

clamping systems for the machining of 

CFRP components 

written by 

Thomas Götz and Andreas Gebhardt, 

Fraunhofer Institute for Manufacturing Engineering and Automation IPA 

The machining of components made of carbon 

fiber reinforced plastics (CFRP) requires the use of 

clamping technology adapted to the task. The following 

article deals with the production of such clamping 

systems by means of a hybrid production of extrusionbased 

3D printing and a machining finishing process. 

CFRP are becoming increasingly widespread due to their 

excellent lightweight construction properties and flexible 

shaping within manufacturing. A significant advantage of 

fiber reinforced components lies both in the possibility of 

designing the construction and material architecture in line 

with the load and in manufacturing the component nearnet-shape. 

However, this results in further necessary processing 

steps for the final completion in the area of the component 

edge as well as for functionalisation, for example by 

inserting holes, pockets or recesses. Machining processes 

are typically used for this, but the processing is associated 

[1, 2] 

with certain challenges. 

Due to the largely open and large-surface design of cfrp 

components, they are usually unstable and prone to vibration 

despite their high rigidity, which impairs both the service life 

of the cutting tools used and the machining quality [3] . 

Clamping systems for CFRP components 

To avoid negative effects during finishing, different clamping 

systems are used (figure 1), which are principally designed 

either on the basis of the geometry of the workpiece [4] and/ 

or the maximum cutting force components resulting from 

the machining process [5] . The state of the art includes, for 

example, jigs that represent a negative shape of the CFRP 

component. This means that the component rests on the 

entire surface and can usually be clamped with low vibration 

by means of vacuum [3] . Since these jigs are milled from 

a plastic or metal block, their production is associated with 

a high time and equipment-specific effort, high costs and 

low resource efficiency. Another unfavourable effect is that 

functionalities such as vacuum fields or channels for suction 

through the jigs can only be produced with great effort [6] , 

as complex, multi-sided drilling and milling operations are 

required. Moreover, the massive and therefore heavy jigs 

can usually only be transported with industrial trucks and 

require adequately designed warehousing and storage logistics, 

which generates further costs [7] . 

jig (A. Gebhardt) 

vacuum clamping system 

(J. Schmalz GmbH) 

mould clamping system 

(MATRIX GmbH) 

figure 1 

llustration of the described clamping systems 


processes 

Against the background of the problems of massive threedimensional 

jigs, developments of modular clamping systems 

for the finishing of CFRP components were advanced 

and marketed. On the one hand, the use of modular clamping 

systems consisting of adjustable vacuum clamps and precisely 

positioned counterholder pins is suitable for secure and 

low- distortion fixing of workpieces with free-form surfaces. 

On the other hand, vacuum clamping systems are being used 

that have rotatable and height-adjustable suction cups, are being 

used, whereby the individual clamping surfaces themselves 

are only flat and thus have limitations in adapting to 

the shape of the component. 

Due to the easy adaptability of the flexible vacuum clamping 

systems to different component contours, they are particul 

arly suitable for small batch sizes. However, given the 

more flexible supports and lower vibration damping, they 

lead to reduced tool life and machining quality. In addition, 

the manual adjustment effort is high, resulting in higher setup 

[3, 7] 

times. 

granular plastics 

extrusion screw 

platform 

extrusion 

unit 

nozzle 

3D object 

In the area of form-flexible clamping systems, there are 

further solutions based on the pincushion principle, which 

allows the fixing of different workpieces by means of grouped 

plungers and adapts to the shape of the component. After 

hugging the workpiece surface, the plungers are locked for 

machining, decoupled at the end of the process and can thus 

move back to their original position [8] . 

In view of the deficiencies of existing clamping systems, 

it may be advisable to first manufacture near-net-shape jigs 

using an additive manufacturing process and then reworking 

the functional surfaces by machining for high dimensional 

accuracy and surface quality. In this way hybrid production 

can significantly shorten the time-consuming and 

labor intensive process chain of component manufacturing. 

Additive manufacturing of 

large-volume components 

Additive manufacturing involves processes in which components 

are built up layer by layer [9] . Depending on the ad ditive 

manufacturing process, the physical principles of producing 

of individual layers differ, whereas the basic process 

figure 3 

Fused granular fabrication [12] 

chain is process-independent and consists of several successive 

steps (figure 2). 

The process begins with a three-dimensional CAD data set 

that represents the component to be manufactured. In the 

following step, the so-called slicing process, the CAD data 

set is divided into layers and contour paths with the help of 

special slicer software. Subsequently, traverse commands, 

consisting of G-code with additional information (print head 

temperature, bed temperature, traverse speeds), are transmitted 

to the printer, which then executes these machining 

instructions. The physical model thus grows layer by layer 

until the component is finished, removed from the machine 

for machining post-processing. [10] 

For the additive manufacturing of large-volume jigs, the 

process of direct granulate extrusion (figure 3) is suitable. In 

this process, thermoplastic standard granulate is conveyed 

CAD model of 

the component 

converting the 3D model 

into printing instructions 

virtual level 

additive manufacturing of the 

component layer by layer 

physical 

component 

physical level 

figure 2 

Process chain of additive manufacturing of components [10] 


35

processes 

through a screw extruder, melted and compacted 

to a homo geneous mass. The melted 

mass is then pressed through a nozzle, whereby 

the discharged material diameter is determined 

by the nozzle’s diameter and the extrusion 

rate. Layer by layer, the plastic mass is extruded 

according to the specified contour data 

on the building platform. [11, 12] Here, the possible 

component size is limited solely by the 

travel distance of the extruder, with a trend 

towards large format additive manufacturing 

with construction volumes ranging from 1 m 3 

up to 25 m 3 [13] . 

(1) static-mechanical 

analysis 

(3) smoothing of 

the mesh structure 

(2) topology-optimised 

analysis 

The granulate-based extrusion process is 

characterized by low costs, the high build-up 

rates (several kg per hour) and the possibility 

of producing large functional and structural 

components. Drawbacks, however, are the low 

resolution and surface quality as well as the 

anisotropy of the components and the associated 

lower strength in the build-up direction 

as compared to the selective laser sintering 

[14, 15] 

process. 

Prototypical production of 

a highly integrative jig 

Starting from the CAD model of a massive 

jig for a complex 3D CFRP component, a topology-optimized 

model was derived using 

the CAD software AUTODESK FUSION 360 

(figure 4). After defining the areas to be retained, 

the geo metrically modifiable design 

space and the mass target (50 %), the vacuum 

clamping and feed forces acting on the jig were 

defined. While the vacuum clamping force 

is applied to the top of the jig as a surface load, 

(4) CAD feedback 

figure 4 

Steps in topology optimization 

the feed force acts tangentially to the machining edge of the workpiece. Subsequently, 

the stress distributions under the defined loads were calculated as 

part of the static-mechanical analysis, a mass-optimized model was designed 

and fed back into a surface model. For the application case of machining, it 

should be taken into account that the feed force has a time-shifted dynamic 

course along the machining edge. Therefore, it can be assumed that the high 

criticality of the load path applies to the entire edge area and is not limited to 

the area shown above. 

Based on the findings of the topology investigation, a mass-optimized jig 

was derived, taking into account manufacturing aspects of additive manufacturing. 

Subsequently, the jig was manufactured using a hybrid production 

sealing cord 

milled surface 

vacuum 

channels 

figure 5 

Additive-subtractively manufactured jig 

tensioning 

template 

connection 

plate 


processes 

process of extrusion-based 3D printing and post-machining 

(figure 5). The jig has a grid-like structure in the areas that 

have proven to be uncritical with regard to the load path in 

the context of topology optimization which simultaneously 

serve as recesses for applying the negative pressure. The 

design also had to take into account process-relevant functionalities 

such as a circumferential groove for receiving the 

sealing cord or an offset as a material addition for the final 

machining of the contact surface of the subsequent component. 

By avoiding support structures and material accumulation, 

a significant reduction in material use and thus also production 

times could be achieved which leads to a further increase 

in the efficiency of the additive manufacturing process 

as com pared to the production of a conventional solid jig. 

In addition, the thermally induced distortion could be 

greatly reduced by optimizing the printing path parameters. 

Summary and outlook 

The potential of additive-subtractively manufactured jigs 

for the machining of CFRP components is already evident. 

The advantages lie in the manufacturability of batch-sizeindependent, 

individual end products, which allow the economic 

integration of functionalities such as vacuum fields, 

milling and suction channels. 

In addition the targeted insertion of hollow structures allows 

significant weight savings, which can lead to easier handling 

and greater material efficiency. 

Further investigations into the general process suitability 

of the jig for real CFRP components, especially with regard 

to the special requirements regarding component sizes in the 

aerospace industry, as well as the circular economy are the 

subject of current and future research work. 

Literature 

[1] 

Spur, G.; Heisel, U.; Klocke, F.; Eckart, U. (2014) 

Handbuch Spanen 

München: Carl Hanser Verlag 

[2] 

Rüger, O.; Fröhlich, F. (2011) 

Endkonturnahe Fertigung von CFK-Bauteilen 

Lightweight Design 4 

[3] 

Moser, S.; Gauggel, C. (2017) 

Die 10 wichtigsten Fakten zur CFK-Zerspanung 

Produktion 14, Internet: 

hwpcom.guehring.de/wp-content/uploads/2018/dokumente/News/Produktion_0417.pdf 

[4] 

Lin, Z.; Yabg, C. (1995) 

An Expert System for Fixturing Design for Face Milling 

Using Modular Fixture 

International Journal of Advanced Manufacturing Technology 

10, 6, pp. 379 - 388 

[5] 

Mahmud, A.; Mayer, J.; Baron, L. (2015) 

Determining the minimum clamping force by cutting force 

simulation in aerospace fuselage pocket machining 

International Journal of Advanced Manufacturing Technology 

80, 9–12, pp. 1751 - 1758 

[6] 

Gebhardt, A.; Schneider, M. (2018) 

Späne- und Stauberfassung bei der CFK-Zerspanung 

wt WerkstattsTechnik online 108, 6, p. 473–478, 

Internet: www.werkstattstechnik.de, 

Düsseldorf: Springer-VDI-Verlag 

[7] 

Götz, T. (2018) 

Entwicklung funktionsintegrierter 3D-gedruckter Spannmittel 

für dünnwandige CFK-Bauteile 

8. IfW-Tagung: Bearbeitung von Verbundwerkstoffen, 

29.11.2018, Stuttgart 

[8] 

Königsreuther, P. (2011) 

Formflexibles Spannsystem passt sich 

jeder Kontur leicht an 

MaschinenMarkt 9, p. 1 - 5, 

Internet: www.maschinenmarkt.vogel.de/formflexiblesspannsystem-passtsich-jeder-kontur-leicht-an-a-333110 

[9] 

Gibson, I.; Rosen, D.; Stucker, B. (2015) 

Additive manufacturing technologies: 3D printing, rapid 

prototyping and direct digital manufacturing 

New York, Heidelberg, Dordrecht, London: Springer 

[10] 

Gebhardt, A. (2014) 

3D-Drucken 

Grundlagen und Anwendungen des Additive Manufacturing 

(AM). München: Carl Hanser Verlag 

[11] 

Weißgraeber, P.; Heieck, F.; Ackermann, C. (2020) 

Advances in Automotive Production Technology – 

Theory and Application 

Stuttgart Conference on Automotive Production 

(SCAP2020) 

[12] 

N. N. 

Fused Granular Fabrication, FGF 

Manufacturing Guide Sweden AB, Stockholm, o. J., 

Internet: https://www.manufacturingguide.com/en/ 

fused-granular-fabrication-fgf 

[13] 

Moreno Nieto, D.; Casal López, V.; Molina, S. I. (2016/18) 

Large-format polymeric pellet-based additive manufacturing 

for the naval industry 

Additive Manufacturing, volume 23, p. 79 - 85, 2018, 

doi: 10.1016/j.addma.2018.07.012 

[14] 

Breuninger, J.; Becker, R.; Wolf, A.; Rommel, S.; Verl, A. 

(2013) 

Generative Fertigung mit Kunststoffen: Konzeption und 

Konstruktion für Selektives Lasersintern 

Berlin, Heidelberg: Springer 

[15] 

Tofail, S. A. M. et al. (2018) 

Additive manufacturing: scientific and technological challenges, 

market uptake and opportunities 

Materials Today, volume 21, n° 1, p. 22 - 37, 2018, 

doi: 10.1016/j.mattod.2017.07.001 

further information: www.ipa.fraunhofer.de 


37

processes 

Design, manufacture and inspection 

in a smart loop 

At JIMTOF 2022 Gleason presented the latest gear 

design, manufacturing and inspection systems in challenging 

times of transformation. Exhibits and live streams 

with KISSsoft’s design software release 2022, new gear 

chamfer cutting technologies, hard finishing of gears 

by Super Finish Honing, Combi Honing and Polish 

Grinding, Hobbing and Power Skiving on one flexible 

platform, revolutionary gear metrology systems with 

laser scanning, sub-micron inspection and in-pro cess 

gear inspection with integrated gear noise ana ly sis. 

KISSsoft® design and transmission software presented its latest 

2022 release with a wealth of new features and functionalities 

including Smart Loop feedback to production machinery 

for fast and efficient design adjustments in the prototyping 

phase, integrating design into manufacturing and inspection 

processes. 

Gleason’s 300GMSL Gear Metrology System features laser 

scanning for gear inspection at the speed of light, providing 

the data for unprecedented real-time analytics to speed up 

the development of complex gears, maximize efficiency, and 

minimize sound emissions in EV and other gearboxes. 

The new 300GMS nano Gear Metrology System provides 

for gear inspection capability at submicron level, integrating 

highly sophisticated tools to analyze waviness for profile, 

lead and pitch, and to determine gear noise characteristics of 

e-drive gears. 

Exhibits were complemented by manufacturing and inspection 

demonstrations via live streams from global Gleason 

operations worldwide presenting new developments in Hard 

Power Skiving, medium size bevel gear cutting, gear honing 

by Super Finishing for excellent surface finishes, threaded 

wheel grinding for gears with mirror-like surfaces and 100 % 

in-process gear inspection. 

On November 10, 2022, Gleason had invited customers 

to the traditional Dr. Stadtfeld Day at Tokyo Big Sight. 

Dr. Stadtfeld presented the latest developments for the future 

of bevel gear manufacturing, including flexible cutting with 

Superi-Ac® Ecoblade RT, psychoacoustic noise reduction with 

MicroformTM, Coniflex® Plus for strong and quiet e-drive 

differentials, bevel gear e-drive concepts and a brand-new 

process for fast cutting of differential gears. 

further information: www.gleason.com 


processes 

Greater efficiency thanks to 

digital assistance systems 

in machine tools 

In the private sphere, digital assistance and communication 

systems have become indispensable. 

In a professional environment, even outside the office, 

supporting systems are increasingly gaining 

equal status. As a machine tool manufacturer, the 

UNITED GRINDING Group offers digital products 

that not only make work easier for its customers but 

also save time and money. 

What makes working on machines in an industrial facility 

easier? “That I can get help quickly and easily when the machine 

stops” could be the answer from a machine operator. A 

maintenance employee may say “That I have an overview of 

all upcoming maintenance tasks and thus no longer miss any 

important schedules”. The answer from the production manager 

might be “That I can also see whether all the machines 

in my production are running when I’m on the road.” 

Different user groups have varying demands on modern 

production. As one of the world’s leading machine tool 

manu facturers, the UNITED GRINDING Group offers 

digital assistance systems that make work easier for various 

user groups. 

Remote service 

Remote service offers uncomplicated and fast assistance, for 

example, in the event of machine downtime. By triggering a 

service request, customers can request quick and uncomplicated 

help by pressing a button. This service request can be 

submitted by the customer via a smartphone and the corresponding 

digital solutions app or via the customer cockpit. 

With a machine equipped with the modern C.O.R.E. technology, 

this is now even possible directly on the machine. In 

addition, a video conference can be conducted via the integrated 

camera in the C.O.R.E. panel. This again significantly 

increases the benefit provided by service support. Also the 

whiteboard function makes it easy to share drawings and 

notes on pictures or documents. This way the customer care 

team can assist remotely, saving time and money. 

Service monitor 

The service monitor relieves those responsible for maintenance 

by displaying clearly all the important maintenance 

tasks based on the current machine’s operating hours. The 

service cockpit can be even used to centrally manage, moni tor 

and document maintenance due dates for several connected 

machines. Only necessary maintenance work is displayed. 

Unnecessary work is thus avoided. But the necessary work 

that ensures the smooth operation of a machine is not forgotten. 

Thanks to this optimal maintenance and care, the availability 

and working life of the machine is increased, which in 

turn has a positive effect on productivity. 

Remote service digital solutions 

Production monitor 

Production managers can monitor the production output of 

the machinery at any time by using the production monitor. 

Production benchmarks, such as operating and non-productive 

times, production quantities and downtimes, are displayed 

in real-time. The latest version also supports the global 

communication standard umati UA4MT (Universal Machine 

Technology Interface for Machine Tools). Not only machines 

from the UNITED GRINDING Group but also machines 

from other manufacturers can be easily integrated 

into the production monitor – from anywhere and at any 

time – thanks to the digital solution app. This overview makes 

it possible to discover optimization potential in the production 

and operation of the machines. 

Growing importance of digitization 

UNITED GRINDING Digital Solutions products were 

presented to an interested audience at the MECSPE 2023 

trade show in Bologna. As a result of the corona pandemic 

the overall importance of digital assistance systems has increased 

noticeably. Remote solutions were the only way to 

stay in contact with customers and provide assistance during 

lockdown periods. During this phase UNITED GRINDING 

had more than 2,500 remote deployments worldwide. The 

trend towards flexible working models and working from 

home or on the road has also driven the demand for appbased 

solutions. Digital assistance systems are already an indispensable 

part of everyday production, and demand will 

be rising. The UNITED GRINDING Group is continuously 

expanding the functionalities of its current products and 

constantly adding to its range of digital solutions. 

further information: www.grinding.ch 


39


Grinding requires smart automation 

Faster, more accurate and more cost-efficient machining 

is only one of the advantages of automating 

grinding processes. Factors such as a higher safety for 

the operators and their health also play a large role. 

STUDER is therefore one of the technology leaders 

in this field. 

“There are still a lot of prejudices about automation in grinding,” 

says Daniel Schafroth, systems division manager at 

STUDER. There are frequently concerns that people or jobs 

could become redundant. “However, for us at STUDER, the 

opposite holds true: automation should enable the human operators 

to do their work more easily, efficiently, and safely,” 

he says. Additionally the special requirement of grinding necessitates 

that automation is used very wisely and selectively 

not every solution used in the industry is suitable for this. But 

what are the important factors? 

“For grinding it is particularly important that processes 

are performed repeatedly in the same way, with high precision 

and reliability, for example clamping workpieces and 

aligning them correctly with micrometer accuracy,” explains 

Schafroth. Automatic solutions for multi-machine operation 

are also relevant, as these can greatly relieve the workload 

of the operators, who then only have to fill magazines 

and no longer need to laboriously load each machine. However, 

grinding fundamentally requires the operators to have 

a high level of competence, and automation should not be 

something that hinders them,” says Schafroth: “Automation 

only makes sense where the operator doesn’t have to have a 

decisive influence on the process.” 

Daniel Schafroth, 

systems division manager, Fritz Studer AG 

Small companies profit from easyLoad 

If correctly used, automation can be a real game changer for 

grinding companies – regardless of whether it is a small business 

or a large company with several systems. “Where grinding 

machines are concerned, automation pays off for all sizes 

of companies,” emphasizes Schafroth. This may mean that a 

small workshop with only a few employees can fill the grinding 

machine in the morning and let it work autonomously 

for extended periods while the employees take care of other 

things, such as writing quotations. For example the easyLoad 

loading system for external and universal cylindrical grinding 

machines (S31, S33, S22 and S41), which offers excellent 

value for money, including integration in the machine control, 

is explicitly also aimed at small companies. 

easyLoad is suitable for use as a gantry loading system for 

shaft parts with a workpiece length of up to 300 mm (11.8“), 0 

up to 30 mm (1.18“), and interfering contour 0 of max. 50 mm 

(1.97”). The adjustable synchronized conveyor allows autonomous 

processing of max. 50 workpieces. The standard gripper 

Adjustable synchronized chain with 

prism supports for up to 50 workpieces 

Loading and unloading situation 

with STUDER roboLoad 



STUDER S31 

with new uniLoad loading system 

STUDER S131 Radius 

internal cylindrical grinding machine 

with roboLoad loading system 

is designed for individual parts, the V-gripper for two parts, 

and the heavy-duty gripper for workpieces that weigh more 

than 5 kg (11 lbs.), and the changeover time is only around six 

seconds. This enables the machine to run autonomously for 

half an hour or longer with ease. 

ecoLoad and uniLoad increase production 

STUDER has also developed optimal automation solutions for 

larger-volume series production. “Small companies mainly 

benefit from the universal and flexible systems, whereas 

speed and precision are the important factors in the production 

of large quantities,” explains Schafroth. Here good automation 

concepts can produce a large number of high-quality 

workpieces and make the most of every second. The ecoLoad 

for the STUDER S22 production platform is an automatic 

loading system for series production using high-speed grinding, 

production-oriented cylindrical grinding, as well as form 

and thread grinding. 

ecoLoad can load workpieces with 0 of up to 50 mm (1.97”) 

and a length of 250 mm (9.85”). This is either done using a 

carousel magazine or an insertion prism, which can also be 

used as the interface for standalone tool magazines. The programming 

is already integrated into the grinding machine 

control. This ensures short retooling times. 

The uniLoad automatic loading system also makes it possible 

for operators of the STUDER S31 and S33 external cylindrical 

grinding machines to significantly increase productivity 

without any loss of quality. The system docks to the 

machine from the left. With a prismatic conveyor and all 

racks at full capacity, it can perform automatic processing 

for around an hour. It is suitable for workpieces with a 

length of up to 350 mm (13.8”) and 0 100 mm (3.94”) and thus 

covers a large range of the parts normally produced on these 

machines. 

Automation when space is tight: 

smartLoad and roboLoad 

Solutions for applications with limited space are another important 

trend in the automation of grinding. “In modern production 

halls, it is of particular importance to make efficient 

use of the space,” says Schafroth. This is another topic where 

STUDER is a trailblazer, for example with the smartLoad for 

the S11, a production cylindrical grinding machine for small 

workpieces which has a footprint of only 1.8 m 2 (19.4 ft 2 ). 

The smartLoad unit is also compact and can feed in workpieces 

from outside the machine, using either a conveyor or 

a swivel ing unit, as well as clamp them and place them back 

after the machining. Thanks to the wide variety of configuration 

options numerous applications are possible, for both 

small and large-volume series. 

Advantages at a glance: 

➤ automation in grinding protects the health of the 

operators and makes their workplaces safer and 

more comfortable 

➤ in small grinding companies with few employees, 

automation gives the staff more time for other tasks 

➤ in large-series production and mass production, 

grinding machines with automation can process large 

quantities very quickly and with consistent quality 

➤ smart, network-capable software and digital assistance 

systems form part of automation, because they make 

the work easier and faster for the operators and 

increase the quality 

STUDER has developed optimal automation solutions for a 

variety of applications: easyLoad (S31, S33, S22 and S41), 

ecoLoad (S22), smartLoad (S11), uniLoad (S31 and S33), as 

well as roboLoad (S121 Radius, S131 Radius, S141 Radius) 


41


In the past, radius internal cylindrical 

grinding machines, which are used in the 

manufacturing of drawing dies, for example, 

have been particularly difficult to automate, 

due to the limited space available. One reason 

for this is the restricted enclosure geometry 

resulting from the high workhead. STUDER 

has now developed an optimal solution for 

this as well: roboLoad. 

This external loader for the S121, S131 and 

S141 is designed as a gripper arm with quickchange 

jaws and has a lot of space for workpieces 

on six trays (each 1080 x 320 mm (42,5 

“ x 12.6”)). At 1.50 m (59”), the system is only 

half the width of the machine itself. 

“With the robot arm outside the machine, 

we gain a lot more freedom, thanks to the 

rotation axis, and the roboLoad can get in 

for loading and unloading without having a 

direct path available,” says Schafroth. Until 

now, automation solutions for grinding were 

largely based on linear technology such as 

beams and slides. However, at the moment the 

roboLoad is not primarily intended for large 

series production, but more for automated 

production during night shifts or extended 

breaks. But Schafroth is sure that the trend 

toward using robotic arms in grinding will 

persist. “Neither our customers nor we want 

to relinquish this new freedom.” 

Automation is digital as well 

This freedom includes easy and intuitive operation, 

a special USP of roboLoad and the 

other STUDER concepts. “The grinding machine 

operators do not need any programming 

skills to perform the setup; it can be 

done easily and quickly within a matter of 

minutes,” says Schafroth. For him, automation 

in grinding means more than just physical 

machine support. It is equally important 

to have digital assistance, such as that offered 

by the STUDER grinding software and in particular 

C.O.R.E., the revolutionary new crossbrand 

hardware and software architecture of 

the UNITED GRINDING Group. 

On the large C.O.R.E. touch display with 

intuitive icons, the operators can quickly 

find what they need and important information 

regarding the machining process is displayed. 

RFID access chips can be used to let 

the machine only display the options and information 

for which the individual users are 

qualified. “This prevents unqualified employees 

from making changes that could cause an 

error or a crash,” explains Schafroth. With 

applications of UNITED GRINDING Digital 

Solutions, efficient remote monitoring of 

STUDER S22 

with ecoLoad loading system on the right 

Grid rack of the STUDER roboLoad 

the machines is possible even today, and in the future machines will monitor 

themselves for optimal functioning and proactively provide information on 

required maintenance measures. 

The possibilities for automation in grinding are therefore very diverse and 

offer large advantages on different levels. However, as Schafroth emphasizes, 

the focus must always remain on people. “Something that is frequently overlooked 

regarding this topic is that automation also protects the safety and 

health of the workers.” Robots can not only help with lifting heavy loads and 

performing repetitive, boring tasks but also handle a wide range of different 

materials without problems. This makes the workplace a lot safer and more 

comfortable. Schafroth says that he is happy that the prejudices regarding 

the topic are decreasing and that automation solutions are becoming more 

and more frequent in grinding, and adds: “Because the best machine technology 

in the world is useless if it is not accepted by the people.” 

further information: www.studer.com 



New femtosecond laser solutions 

On February 21, 2023, at an Open House event 

held in its Laser Center of Technologies in Geneva 

(Switzerland) with more than 70 international VIP 

guests, GF Machining Solutions presented its new 

LASER S 1000 U fs and LASER S 1200 U fs machines 

in an exclusive preview. The two solutions are equipped 

with new ultrashort pulse laser sources and are now 

available for sale. 

The 

launch of 

the two new laser 

machines is expected to 

increase the adoption of laser 

in industries such as automotive, 

for example for lighting molds 

Ultrashort pulse laser sources are well known for their 

excellent machining quality, achieving finest details and 

better surface roughness compared to nanosecond laser 

sources. The first machine equipped with an ultrashort pulse 

laser was the AgieCharmilles LASER P 400 U, which introduced 

this powerful tool for texturing and engraving into the 

market. 

Thanks to latest developments, GF Machining Solutions’ 

AgieCharmilles LASER S 1000 U fs and AgieCharmilles 

LASER S 1200 U fs are now also equipped with a fiber femtosecond 

laser. This will ensure a laser machining process 

capable of creating finest details with enhanced quality while 

maintaining a high performance. It will also allow the processing 

of a wider range of materials that only femtosecond 

laser sources are able to machine efficiently, like ceramics, 

glass, sapphire etc.. 

The launch of these two new machines is expected to 

increase the adoption of laser as a technical manufacturing 

solution in industries such as automotive (for lighting, interior 

and exterior design), packaging and ICT. Nanolaser 

capabilities often could not satisfy requirements like the 

machining of complex, small geometries, a no-heat affected 

zone and the necessary surface roughness needed for applications 

in these industries. 

Users will maintain the upmost flexibility thanks to the 

possibility to combine a nanosecond and a femtosecond laser 

source in the same machine, switching seamlessly between 

the two sources in the same job. Depending on the appli - 

cation and the desired results, it is possible to use the 

strengths of each laser source for the best combination of 

quality and productivity. The new femtosecond options 

work in perfect union with the latest software developments 

launched by GF Machining Solutions in 2022: flexiblast TM 

and 3DCurves TM . 

Thanks to the new 

machines, the crewith 

enhanced quality, 

shown on this lotus flower, 

capabilities of the 

ation of finest details 

like the ones 

will be possible 

“We believe that the new femtolaser capabilities that we are 

integrating into our large laser machines will not only meet 

the needs of our existing customers active in laser texturing 

and engraving, but also open up space for new applications 

in micromachining, attracting new customers in further segments 

like semiconductors or aerospace”, says Stefan Dahl, 

COO of GF Machining Solutions. 

The LASER S 1000 U fs and the LASER S 1200 U fs 

do not only offer extreme machining speed, but can also 

achieve higher quality and better surface roughness 

thanks to the new laser sources 

further information: www.gfms.com 


43


The European debut of the 

Supfina Fact 

As one of the global leaders in surface finishing 

technologies, the Supfina team presented an innovation 

to interested parties at Global Industrie 2023. The 

new Supfina Fact superfinishing attachment was presented 

to the European professionals for the first time. 

Fast action changing tool 

With its small, compact design the Supfina Fact tape finishing 

attachment is ideal for use in revolver lathes. Additionally 

the surface qualities that can be achieved are much higher 

than those achieved with standard turning. This means that 

even the highest surface requirements will be fulfilled. 

Functionally perfect surfaces 

Whether it’s low-volume attachments or complete machining 

solutions with automation, Supfina works together with the 

clients to review their existing production structure and meet 

any requirements in the following areas: 

➤ superfinishing 

➤ flat finishing 

➤ fine grinding 

➤ double-disk grinding 

➤ attachments 

➤ automation and robotics 

Solutions from a single source 

As a solution provider Supfina advises prospects and customers 

on their individual challenges, validates parameters and 

uses its own studies to develop the appropriate machining 

solution. In addition, a later integration into existing production 

structures, sustainable automation and IT infrastructure 

is taken into account. 

Superfinishing attachment fact 

➤ small compact design for mounting on the 

revolver of lathes 

➤ drive for the oscillation and the tape feed via 

a central drive from the revolver of the lathe 

➤ flushing through the revolver to the pressure roller 

➤ no additional media connections are required 

➤ adaptation to different turret systems possible 

➤ oscillation shutdown for twist-free machining 

through special gear is possible 

In particular the automation of loading and unloading 

through robot-assisted process automation is currently 

a strong demand f.e. due to the lack of skilled workers. “Our 

customers are increasingly demanding sophisticated systems 

for their production processes,” explains Dominik 

Maier, business unit manager, “whether complex automation 

or upstream and downstream processing, we deliver the 

solution.” 

A comprehensive, modern range of services is available, 

from maintenance to production and process support to 

individual training. 

further information: www.supfina.com 


Precise sharpening for wood and co. 


In the wood industry, circular saws, drills or 

milling cutters are indispensable for the efficient processing 

of wood and composite materials. Visitors to 

LIGNA 2023 woodworking trade fair can find out how 

these tools can be machined with the highest precision 

at the international sharpening specialist Vollmer. 

The company will be providing comprehensive insights into 

its range of machines with which customers can machine 

their circular saws and rotary tools – regardless of whether 

these are made of carbide, PCD (polycrystalline diamond) or 

other cutting materials. Automation enables unmanned 24/7 

shifts and digital V@dison solutions optimise tool machining 

and increase transparency through the rapid availability of 

machine data and information. 

Grinding and eroding machines for 

drills and milling cutters 

In addition to circular saws, drills and milling cutters are 

also used for cutting wood and composite materials. Vollmer 

has developed its VGrind grinding machines to produce 

rotary tools such as these from carbide. They have two vertically 

configured grinding spindles and allow efficient multi - 

level machining. This time the VGrind argon will be at LIGNA 

trade fair. 

The VHybrid 260 grinding and eroding machine also 

features multi-level machining, with the lower spindle 

capable of both grinding and eroding. Thanks to a new 

V@dison solution, the VHybrid 260 achieves a surface finish 

of 0.05 μm/Ra (micron/center roughness value) when eroding 

PCD tools. Also on show at LIGNA is the QXD 250 disc 

erosion machine, which is suitable for sharpening PCD tools 

with diameters of up to 320 millimeters and weights of up 

to 25 kilograms. 

Vollmer provides information about its services 

Vollmer’s presence at LIGNA fair will be completed with 

services for maintenance, servicing, training, financing and 

digitalisation. Among them are offers of the V@dison digital 

initiative, which include, for example, the “Performance 

Package for VHybrid 260” V@ boost solution. 

further information: www.vollmer-group.com 


45

components 

Filtration solutions for coatings and 

finish applications 

State-of-the-art filtration solutions seal the deal between 

improved performance and sustainability 

in industrial applications 

The Filtration Division of power management 

company, Eaton exhibited how its filtration solutions 

designed for coatings and finishes applications help 

improve performance and sustainability at European 

Coatings trade show in Nuremberg, Germany. 

The exhibition program included diverse and effective filtration 

solutions for removing solids and oil from paint, coatings, 

varnishes, adhesives, sealants, additives and printing 

inks. These solutions allow for more efficient production 

lines, less maintenance downtime and reduced waste. 

The focus was on Eaton’s comprehensive bag filtration solutions. 

Eaton’s TOPLINE single bag filter housing is designed 

for a large variety of applications and can either be used as 

a single housing or connected in a parallel arrangement. 

It features a side inlet, flow-through top for easy and quick 

filter bag change-outs and provides optimum sealing of the 

filter bag to help prevent product loss. To meet the special 

filtration requirements of paints, coatings and varnishes 

in the automotive industry, it can be equipped with highstrength 

filter bags from the LOFCLEAR 100 (automotive) 

range. When used with Eaton’s HAYFLOW filter elements or 

MAX-LOAD pleated filter bags, the number of change-outs 

can be reduced, resulting in improved operating efficiencies, 

reduced operation costs, and reduced waste volume. 

Eaton’s extended-life, pleated MAX-LOAD 

needle-felt filter bags with outer cage, SENTINEL seal ring 

and thermo-bonded end caps for maximum 

dirt-holding capacity even under harsh conditions 

Eaton’s PED-compliant Simplex 72X pipeline basket 

strainers in ductile iron and stainless steel are designed 

to protect process equipment in various chemical, 

petrochemical and water applications 

Another highlight was Eaton’s automatic filter family for 

processes where a complete shutdown is not an option. A part 

of this automatic filter family showcase is the range of DCF 

mechanically cleaning filters that is ideal for highly viscous, 

abrasive, or sticky liquids – including paint. It operates at a 

consistently low differential pressure and deliver simple, reliable 

operation in which a low initial investment is a key driving 

factor. 

The exhibition program was rounded off with the Simplex 

72X cast pipeline strainer range. It is available in six standard 

sizes and conforms to the Pressure Equipment Directive 

(PED) with sealing and surface finishing characteristics, superior 

to previous models. The strainer range is CE-marked 

to PED and is compliant with the EN13445 and AD 2000 

pressure vessel codes. The Simplex 72X strainers provide 

full bypass-free filtration which protects process equipment. 

Typical applications for the strainers include chemical, petrochemical 

and water pipelines where temporary shutdown for 

cleaning or changeout is possible. 

further information: www.eaton.com 


The world’s first e-chain made entirely of recycled material 

Conserving resources and 

extending the product life cycle 

components 

More sustainability with consistent quality: the new cradle-chain 

made of recycled material conserves resources and drives 

the circular economy forward 

Cradle-to-cradle: this is the principle of the circular 

economy which is abased on nature. The aim: to return 

consumer goods to the biological or technical cycle in 

order to conserve valuable resources and raw materials. 

The motion plastics specialist igus is also pursuing 

this goal and has now developed the world’s first energy 

chain made from recycled material on the basis of its 

own “chainge” e-chain recycling program. 

From extreme weather and natural hazards to marine pollution, 

the climate crisis is getting worse and more and more 

people are becoming aware of it. “Even the purchasing decisions 

of our customers are increasingly being shaped by ecological 

considerations. That is why we have put a lot of effort 

into product development in order to be able to produce more 

resource-efficiently – without sacrificing product quality,” 

explains Jörg Ottersbach, head of the igus e-chains business 

unit. The result: the E2.1.CG cradle-chain – a complete 

range of e-chains made from the new igumid CG material. 

Numerous tests in their test laboratory show that the new 

e-chain has almost the same technical properties and load 

limits as an energy chain made from the standard igumid G 

material. Another advantage is that the cradle-chain is available 

at the same price as e-chains made from the standard 

material. The new range is available from stock in five series 

and 28 chain types. 

From discarded e-chain to recycled material 

The cradle-chain uses, among other things, recycled material 

from the “chainge” recycling program. As part of this 

program igus has been collecting used energy chains from 

customers since 2019 so that they will not end up in industrial 

waste. This service is offered for both igus e-chains and 

chains from other manufacturers. So far more than 32 tons 

of material have been collected from 13 countries. 

Scrap material is sorted by type, cleaned and processed to 

new quality. This is possible with the help of a chemical analysis 

and formulation tuning, a process in which material is 

optimized for the desired properties and therefore enables 

constant product quality. The post-consumer material igumid 

CG is then used to make the recycled cradle-chain – without 

any loss of quality in terms of wear behaviour, stability or 

bending fatigue. 

Sustainable raw material cycle – 

with 28 % less CO 2 

With the new e-chain product range made of recycled material, 

igus is making a further contribution to conserving 

resources and advancing the circular economy. According 

to the Environment Product Declaration, this sustainable 

raw material cycle also reduces CO 2 emissions by 28 %. Jörg 

Ottersbach says, “The focus should not only be on first use 

of products, but also the reuse of raw materials. We see a lot 

of ‘cradle-to-cradle’ potential and strive to reprocess as many 

raw materials and discarded products as possible so that 

precious resources are not waste, but used wisely for as long 

as possible.” 

further information: www.igus.eu 


47

components 

The ES951 spindle and MyHSD, 

a high performance combination 

We have entered the heart of the production plants 

of Mecal Machinery srl and Oddicini srl, two Italian 

companies based respectively in Frascarolo (PV) and 

Gravellona Toce (VB), which have been choosing and 

relying on HSD technological solutions for years. 

In particular Mecal Machinery is a company specialized 

in the production of machines and systems for processing 

aluminium, PVC and light alloys. Oddicini, using Mecal 

machinery, is a company that creates operable partitions, 

customizable with any finish and raised floors designed for 

any use. 

Meeting Rosella Meschini, co-owner and sales director of 

Mecal Machinery, and Susanna Cane, CEO of Oddicini, we 

had the opportunity to investigate and explore the experience 

of two consolidated customers who have chosen to use within 

their production processes HSD components; and more 

specifically, to discover the innumerable advantages deriving 

from the new ES951 wi-fi electrospindle connected to the 

IoT platform, MyHSD. The ES951 range of electrospindles, 

developed to equip 3-axis machining centers and robotic 

applications, offers the possibility of choosing from a wide 

range of motorizations and is characterized by an integrated 

IoT system. 

First of all, Mecal Machinery chose to incorporate the new 

wi-fi electrospindle into its machining centers, immediately 

understanding the great added value that this would generate 

for its machinery, helping to improve performance and quality 

standards. “The new ES951 spindle and the My HSD platform 

are a high-performance combination because we are 

going to combine the performance of the spindle with 

the possibility of detecting all the data that it can transmit 

remotely, making it possible to monitor everything that is 

happening on the spindle in realtime” – Davide Rubin, UTE/ 

service manager Mecal Machinery srl. 

The MyHSD platform was developed with the aim of “providing 

our customers with a wide range of services and benefits, 

such as reduction of maintenance costs, real-time data 

analysis to convert them into useful information, improvement 

of customer knowledge on the use of the electrospindle 

and the provision of useful information for research and development, 

to improve processes and optimize maintenance 

through timely notifications and guided troubleshooting 

procedures” – Fabrizio Pierini, general manager of HSD. 

These advantages are inevitably crucial not only for 

Mecal, but also and above all for those who use Mecal machinery 

equipped with the HSD wi-fi spindle, such as Oddicini 

for example. In fact, what prompted the Piemontese company 

to choose this combination within its machining center 

was “the possibility of preventing breakdowns, because 

in the company, unfortunately, machine downtime due to 

a sudden breakdown represents considerable damage to the 

production and to the consequent costs for management” – 

Susanna Cane, CEO of Oddicini. 


components 

The monitoring offered by MyHSD does not just avoid failures, 

but it anticipates them. The predictive maintenance 

strategies exploit the innovative e-core sensor technology, 

which combined with distributed algorithms between platform 

and device, provide the user with timely notifications 

on the replacements to be made, thus maximizing the machine 

up-time. The HUB function, patented by HSD, allows 

to transfer machine tool information to the MyHSD platform 

such as: process data, statistical values and the status 

of the machining center. This feature allows to exploit the 

potential of MyHSD not only on the spindle but also on the 

machine. Furthermore, the MyHSD premium package embraces 

a holistic approach to predictive maintenance, providing 

the operator with a complete overview of the entire 

system, and also ensuring a greater capacity for prediction 

and analysis, thus favouring a drastic reduction of potential 

financial losses. 

Using the computer or smartphone application, the user is 

able to “see the vibration levels of the spindle, how many rotations 

it is working at and if we are carrying out particularly 

complex or heavy machining” – Gabriele Morandi, maintenance 

manager of Oddicini srl. A combination between the 

ES951 wi-fi electrospindle and the MyHSD platform, capable 

of increasing the performance of the machining center 

on which the spindle is installed and significantly improving 

LIGNA 2023 

HSD products dedicated to wood processing include the 

Wi-Fi ES951 range of electrospindles designed to equip 

3-axis machining centers and robotic applications, 

offering to choose from a wide range of motorisation 

options. Customers can configure their electrospindle with 

3-phase asynchronous motors and power ratings from 

6.5 kW – 25 kW, and select compressed air, electric fan 

or liquid cooling systems. The entire ES951 range allows 

interaction with the machine via a selection of IoLink, 

Ethercat or Canopen fieldbuses, offering a version with 

an HSD-produced MEMS accelerometer and a thermal 

probe to monitor the temperature of the front bearings 

among other options. 

The ES951 electrospindle range also features an integrated 

IoT system for connecting to the My HSD IoT platform for 

a high-performance combination. In this arrangement 

the spindle can capture all the data, allowing real time 

monitoring on the spindle. 

the use of the machinery by the end user, having the ability 

to promptly implement any corrective actions to prevent and 

avoid breakdowns and consequent machine downtime. 

Digitization and connectivity are nowadays essential 

elements to consider in the offer of a product, capable of simplifying 

the processes of the customers and consequently 

improving their competitiveness on the market. 

HSD has been a forerunner of the industrial digitalization 

with its e-core products on the market for over 10 years 

and today, with the ever-increasing development of the IoT 

world, it is able to offer its customers the innovative MyHSD 

predictive maintenance platform. A platform whose application 

will also be extended from 2023 to other models of electrospindles, 

such as those dedicated to metalworking, with 

the ultimate aim of meeting and increasingly satisfying the 

different needs of the customers 

further information: www.hsd.it 


49

components 

Coolant filtration as a value-adding factor 

Optimally filtering and cleaning cooling lubricants 

Vomat demonstrated high-performance ultrafine filtration technology during GrindTec 

In tool grinding all influencing parameters in the 

overall cutting chain must be perfectly coordinated. 

Cleaned coolants and lubricants are an important 

piece in the mosaic. At GrindTec 2023 the filtration 

specialist Vomat from Treuen showed solutions on 

how tool manufacturers can realize high quality and 

economic efficiency with optimally filtered coolants. 

In tool grinding coolants are on the one hand a cost factor 

and on the other hand an important quality-determining 

parameter, and the longer the cleaned coolant can remain in 

the system the less coolant it requires, storage and recycling 

costs are reduced, and also the grinding wheels do not have 

to be changed or dressed as often. 

Steffen Strobel, technical sales manager at Vomat says, 

“Vomat FA filtration systems are ideal for filtration of ultra-fine 

particles from grinding oils. Important features include 

full-flow filtration with 100 % separation of dirty and 

clean oil, on-demand filtration and backwashing of the highperformance 

precoat filters, and high-precision temperature 

accuracy.” 

On the standard platform of the FA machine series, individually 

tailored concepts – from small-scale systems to 

industrial central filtration solutions – can be configured 

thanks to a wide range of optional add-on modules. 

further information: www.oelheld.com 


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3M ................................ 20 

Boehlerit GmbH & Co. KG ............18 

CemeCon AG. .......................16 

CERATIZIT 

Deutschland GmbH .................6 

Deutsche Messe AG ..................26 

EATON Corporation ................ 46 

Fraunhofer Institute for Manufacturing 

Engineerig and Automation IPA .....34 

Fraunhofer Institute for 

Surface Engineering and 

Thin Films IST .....................33 

Fritz Studer AG ................. 22, 40 

GEFERTEC GmbH ................. 24 

GF Machining Solutions .............43 

Gleason Corporation ................38 

Hartmetall-Werkzeugfabrik 

Paul Horn GmbH ........... 14, 15, 23 

HSD S.p.A. ........................ 48 

company finder 

Hyperion Materials & 

Technologies, Inc. ..................13 

igus® GmbH. . .......................47 

Lach Diamant Jakob Lach 

GmbH & Co. KG ...................28 

Leitz GmbH & Co. KG ...............12 

Leuco Ledermann GmbH & Co. KG ....10 

Liebherr-Verzahntechnik GmbH ......17 

LMT Tools GmbH & Co. KG ...........9 

MAPAL Fabrik für Präzisionswerkzeuge 

Dr. Kress KG ...................21, 23 

Messe Stuttgart ......................27 

oelheld GmbH ......................50 

Supfina Grieshaber GmbH & Co. KG .. 44 

UNITED GRINDING Group .........39 

VDW – Verein Deutscher 

Werkzeugmaschinenfabriken ........25 

VOLLMER WERKE 

Maschinenfabrik GmbH ........ 24, 45 

ZOLLER GmbH & Co. KG ............27 

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advertising index 

CERATIZIT Deutschland GmbH ......................................front cover 

Kapp GmbH & Co. KG ..................................................page 9 

Lach Diamant Jakob Lach GmbH & Co. KG ............................. back cover 

rose plastic AG .........................................................page 15 

ZECHA Hartmetall-Werkzeugfabrikation GmbH ..........................page 13 


51

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