hp tooling 2025-#4

ISSN 2628-5444
high precision tooling
Machine Tools, PCD, PVD, CVD, CBN, Hard Metal 2025 – 4
■ Humanoid robots: “vision and reality” ■ Precise measurement of hypotubes ■ New standards in tool processing ■
■ Stator machining solution ready for series production ■ Quality and efficiency for internal gears ■

... a must have for turning aluminium
®
®

editorial
Eric Schäfer
editor-in-chief
The mood is not exactly buoyant
Anyone who had hoped that the recent EMO would bring
about a change to the industry’s mood was quickly proven
wrong when touring the exhibition grounds and talking
to people. Caution remains the prevailing mood. However,
EMO did demonstrate that “smart and impressive technical
solutions are available in abundance,” as EMO general
commissioner Carl Martin Welcker stated at the opening
of the world’s leading trade fair for production technology.
These solutions should make people excited about the future,
however no one seemed confident. In other words, the
investment booster just isn’t catching on, yet.
Uncertainty about the political development continues
to hinder investment, at least in Europe. Outside of Europe
there is more confidence. More than 60 % of surveyed foreign
visitors to EMO plan to invest. This is reflected in the
current growth of foreign orders in the German machine
tool industry. In the first seven months of this year, foreign
orders increased by 6 % compared to the same period last
year. In contrast, demand from Germany fell by 22 %
during that same period.
The “smart and impressive technical solutions” mentioned
above have the potential to finally provide the impetus
for innovation that will enable us to address some of
the challenges of our time in a progressive, sustainable
and efficient way. Those who are willing to take risks
when investing, who do not retreat but recognize new
opportunities, will be optimally prepared when the
mood improves.
Eric Schäfer
editor-in-chief

table of contents
cover story
Wire and sinker EDM crown the precision engineering services 6
materials & tools
New BasicDrill: customized configuration, fast delivery 8
New tungsten carbide grade for superalloy machining 9
New systems for milling, grooving and parting off 10
Tradition. Passion. Innovation: LACH DIAMANT® – 100 Years – 14 th part
How a mishap became a stroke of luck for the birth of the »Dia-Monoblock« milling cutter 12
processes
Quality and efficiency for internal gears 24
Stator machining solution ready for series production 26
Enhanced stability and cleanliness 29
Specialists in ultrasonic deburring 30
machining center
High-end wire EDM for the highest levels of precision 33
“Experience sparks intelligence” 36
New standards in tool processing 39
Five-axis machining with the highest precision in a new dimension 42
components
Medical technology: 3D measurement technology for high-resolution surface analysis
written by RJ Hardt 44
New module for optimizing CAD tool data 47
Customized and resource-saving cooling lubricant microfiltration for every size 48
All eyes on extraction efficiency and ease of use 49
news & facts 16
fairs 5, 22, 23
impressum & company finder 51
4 no. 4, November 2025

fairs in alphabetical order
AMB Stuttgart, Germany
(September 15-19, 2026)
CIMT Beijing, China
(April 12-17, 2026)
EPHJ Geneva, Switzerland
(June 16-19, 2026)
FABTECH Toronto, Canada
(June 16-18, 2026)
current status
2026
2026
2026
2026
FEIMEC Sao Paulo, Brazil
(May 5-9, 2026)
FILTECH Cologne, Germany
(June 30-July 2, 2026)
glasstec Düsseldorf, Germany
(October 20-23, 2026)
GrindingHub Stuttgart, Germany
(May 5-8, 2026)
Hannover fair Hanover, Germany
(April 20-24, 2026)
HIMTEX Hyderabat, India
(August 20-24, 2026)
IMTS Chicago, USA
(September 14-19, 2026)
JIMTOF Tokyo, Japan
(October 26-31, 2026)
MACH-TECH and Budapest, Hungary
INDUSTRY DAYS (May 18-21, 2026)
METALEX Bangkok, Thailand
(November 19-22, 2025)
NORTEC Hamburg, Germany
(February 3-5, 2026)
SIAMS Moutier, Switzerland
(April 21-24, 2026)
SIMTOS Seoul, South Korea
(April 13-17, 2026)
sps Nuremberg, Germany
(November 25-27, 2025)
SteelFab Sharjah, United Arab
2026 (January 12-15, 2026) Emirates
Stone+tec Nuremberg, Germany
(Juni 17-20, 2026)
Surface Stuttgart, Germany
Technology (June 9-11, 2026)
TMTS Taichung, Taiwan
(March 3-7, 2026)
2026
2026
2026
2026
2026
2026
2026
2026
2026
2025
2026
2026
2026
2025
2026
2026
2026
2026
trade fair dates as by end of October 2025; we are not responsible for reliability of these dates
no. 4, November 2025
5

cover story
Wire and sinker EDM crown the
precision engineering services
Switzerland is a birthplace of precision mechanics,
from watches and machine tools to railway technology.
Due to the widespread passion for accuracy and
tinkering, you can find even in smaller communities
craft businesses that produce flawless high precision.
This is also true in the partly rural town of Herisau. In
the basement of a multi-family house with an extension,
there is a small yet highly efficient precision engineering
workshop. Here ten employees manufacture
custom high-tech components for the medical technology,
precision mechanics and mechanical engineering
industries.
“We started in 1964 purely as a contract manufacturer for
stamping tools. Since then we’ve evolved into a versatile producer
of complex precision components”, says Roger Brändle,
operations manager of Amiet Präzisionswerkzeugbau AG in
Herisau, Switzerland. The small company currently operates
four Mitsubishi wire EDM machines: a FA20, over 20
years old, two MV1200Rs and a MP2400 Connect acquired
in 2023. Additionally they have a Mitsubishi sinker EDM
machine, the SG12S, and an older start-hole drilling machine.
The ten employees also have access to a wide range of
CNC-controlled machine tools and the 3D-CAM software,
with three workstations in the office and three more directly
at the EDM machines.
Broad range of technology
“To meet the diverse needs of our customers, we use a variety
of other technologies”, adds Bruno Bon, wire EDM specialist
at Amiet. Their equipment includes two 3-axis and two 5-axis
CNC milling centers, four CNC lathes, a CNC cylindrical
grinding machine, and two laser engraving systems. In addition
they have conventional cylindrical and surface grinding
machines and a highly accurate Wenzel LH 65
coordinate measuring machine, located in a separate,
climate-controlled room.
High-precision land: operations manager Roger Brändle
inspects a diamond ball with a diameter of only 1.4 mm,
machined using wire EDM
A key feature of Amiet is flexibility and quick response,
especially for urgent orders. Customers benefit from a flat
hierarchy and extensive machinery. A particularly important
asset is their in-house heat treatment facilities, including
a high-tech hardening system with a pressure chamber up to
5.5 bar, offering case hardening, hardening and tempering in
a protective gas, and vacuum hardening and tempering. They
also have conventional hardening and tempering ovens with
The cutouts of this crimping tool
feature a polygonal geometry
6 no. 4, November 2025

cover story
The 1.4 mm diameter diamond ball, soldered onto a
brass carrier, was machined using a rotary device on
a MV1200R through electrical discharge machining
The designer is only concerned with the narrow metal strip with
the cutout; Amiet recommended a more suitable material and
designed a clamping fixture in which 20 sheets could be
stacked and cut simultaneously
protective gas supply, and quenching can be done in air or oil.
This complements the variety of materials they handle, with a
focus on steels and special steels, including powder-metallurgical
materials. Thanks to their in-house hardening capabilities,
Amiet can respond quickly and flexibly to deadlines,
occasionally conducting hardening treatments overnight.
Besides steel they also work with various non-ferrous metals
and special materials. Their clients come from sectors such as
medical technology, food processing, mechanical engineering
and occasionally stamping and forming technology.
Partnership in development with customers
“Consulting with our customers is a natural part of our service
package”, explains Roger Brändle. Sometimes, when an
inquiry comes in, it’s clear that alternative material choices or
geometry options could make the component easier, cheaper
or faster to produce. In such cases they work with customers
to find optimal solutions. For instance, long, thin contours cut
from solid material using wire EDM need careful consideration
of geometry changes due to released internal stresses.
For smaller parts or complex geometries, the order of processing
steps can also be critical. Clamping techniques can
be particularly challenging when dealing with components
measuring just a few millimeters or even fractions of a millimeter.
The Amiet team is always ready to offer customers
useful advice and suggestions for improvement from the moment
an inquiry is submitted.
With a grand designs you need someone strong to count on
Since 1970 a growing number of European companies
have turned to high-performance EDM machines from
world market leader Mitsubishi Electric.
Only by producing components in-house is it possible
to tailor them perfectly to the intended task. The company
resorts to its own controls, semiconductors, motors and
other items, which are adapted in detail to all requirements.
The only thing to notice is that it works – and often for
many decades after purchase.
Choosing the Mitsubishi Electric MP2400 Connect
“We were one of the first users of Mitsubishi wire EDM
machines in Switzerland”, recalls Bruno Bon. The recently
purchased MP2400 Connect is the seventh machine they’ve
sourced from the japanese manufacturer. The older machines
were decommissioned after more than 20 years of service due
to increasing maintenance needs, but they were still in good
enough condition to be sold. The motivation behind acquiring
the MP2400 Connect was its higher precision and performance
compared to their existing systems.
In addition to its high accuracy of 2 µm, the new machine
impressed them with its precise rethreading in the cutting
gap, even for tall and interrupted workpieces. Other advantages
included the superior surface quality of cut edges, up
to Ra 0.05 µm, and the automatic power unit adjustment to
accommodate variations in wall thickness. They also experimented
with alternative wire diameters on the new machine,
achieving up to 20 % faster cutting speeds by using 0.3 mm
wire instead of the standard 0.25 mm. The highly reliable
automatic threading allows for long jobs to run overnight or
over the weekend.
A reliable technology partner
“When looking for a new machine we did consider other options”,
reveals Bruno Bon, but after thorough evaluation they
decided to stick with their long-time supplier. Ultimately
their many years of positive experience with the precision
and reliability of Mitsubishi Electric’s technology were decisive.
Even when issues arose, service was fast and competent.
Other advantages included excellent hotline support and
the familiarity of the team with operating the machine.
Since installing the new MP2400 Connect there were hardly
any problems. “With Mitsubishi we have a partner that provides
powerful and reliable technology and is quick to offer
help and advice when needed – and that’s what counts”,
concludes Roger Brändle.
www.amiet-ag.ch / www.mitsubishielectric-edm.de
no. 4, November 2025
7

materials & tools
New BasicDrill:
customized configuration, fast delivery
As part of its product launch of solid carbide drilling
tools, EMUGE-FRANKEN is breaking new ground
with the new BasicDrill CM-C step drill: for the first
time customers can configure a universally applicable
twist drill themselves according to their individual
requirements.
Customers can configure the new BasicDrill CM-C step drill
themselves according to their individual requirements
Customers can select various diameters, cylindrical drilling
depths and step angles, different shank types and with or
without corner protection. This mechanical reinforcement
protects the cutting edge from wear and chipping under strong
radial and axial forces – for example with high-strength and
abrasive materials.
The drill is equipped with a cutting edge in basic geometry
for a wide range of applications and has four margins for precise
drilling. Its integrated cooling channels and high-performance
coating guarantee high process reliability. Production
of the customized drill starts within 24 hours and it is
delivered in less than four weeks.
Unique offer
The BasicDrill CM-C is aimed at both small and mediumsized
machining companies but also manufacturers of large
series who need tools quickly for testing purposes.
According to Martin Steinbach, product manager Drilling
Tools at EMUGE-FRANKEN, the service is currently unique
on the market: “I am not aware of any individually config -
urable twist drill that customers can get delivered so quickly.”
Numerous options to choose from
The tools are categorized into size groups of uniform
length, each of which is offered at a fixed price. The customer
can choose freely between nominal diameters of 2.80 and
18.00 mm as well as step angles in a range 30 ° to 160 ° .
The BasicDrill CM-C is designed as a universal drill for
steel and a variety of other materials, including
cast materials and stainless steels
The cylindrical drilling depths always start at 4 mm; the
maximum is between 11 mm and 54 mm, depending on the
diameter. The overall lengths vary from 57 mm to 131 mm,
the shank diameters from 6 mm to 20 mm.
All variants are available with or without corner protection
and in HA, HB and HE shank types.
Versatile universal drill
The BasicDrill CM-C has been designed as a universal drill
for steel and a wide range of other materials, including cast
materials and stainless steels.
It is used for drilling and pre-tapping operations in numerous
fields of application. These include, for example, the machining
of gear wheels and drive trains in vehicle and mechanical
engineering. However, this universal tool is also used
for machining tasks in energy production and machining as
well as in the aviation industry.
Production of the customized drill starts within 24 hours
and the drill is delivered in less than four weeks
Automated processes
The short delivery times are made possible by an automated
workflow from ordering to production and dispatch. The
service is offered under the brand name “Quickline”.
further information: www.emuge-franken.com
8 no. 4, November 2025

materials & tools
New tungsten carbide grade
enhances cutting tool performance
for superalloy machining
Hyperion Materials & Technologies, a leading global hard materials
company, announced the launch of grade AM10F tungsten carbide
rod tool blanks that raise the bar for machining heat-resistant
superalloys (HRSAs) and other advanced materials.
Engineered for high-performance round tools used in aerospace, energy,
marine and other demanding industries, carbide grade AM10F exhibits increased
wear resistance that keeps cutting edges sharper longer to allow manu -
facturers to maximize production efficiency and reduce scrap costs.
“We work continuously with our toolmaking and manufacturing partners
to achieve optimal solutions through longer, more consistent tool life”, said
Biju Varghese, Hyperion senior vice president who oversees the company’s
product management and research and development teams. “We’re excited
to align the introduction of grade AM10F with EMO Hannover in Germany,
where we can connect with many of our current and prospective production
technology partners”, Hyperion tapped decades of hard materials expertise
and tight manufacturing process controls to develop carbide rod blanks
in grade AM10F to excel in tools used to cut HRSAs such as Inconel, Monel,
René, Nimonic, Hastelloy and Haynes. In side milling tests performed
on Inconel 718, Hyperion compared tool performance and reliability using
carbide grade AM10F and two premium substrates from competitors. Tools
made of AM10F lasted more than 50 % longer with far greater tool life predictability.
Material analysis revealed the more consistent microstructure and
chemistry of AM10F translated to predictably long tool life.
Performance
without
limits.
TAKE CONTROL OF
PRECISION MOTION FOR
LASER MICROMACHINING.
“For customers that work with notoriously difficult-to-cut materials that
wear out tools quickly and increase the risk of unexpected failures that can
lead to scrapping high-value components, grade AM10F’s ability to deliver
predictable results with cutting edges that break less often will be a game
changer.” said Susanne Sowers, Research & Development director who managed
the development of the new product. “This is a market-leading product
that will empower cutting-edge toolmakers to drive performance improvements
that will increase productivity and cost savings for manufacturers.”
Carbide rod blanks in grade AM10F are the newest addition to Hyperion’s
Application Specific series of carbide rods engineered for fabricating highperformance
tools used to machine advanced materials. Carbide rod blanks
in grade AM10F deliver:
• superior wear for enhanced resistance to chipping, making it the ideal
substrate for high-performance cutting tools used in aerospace, energy,
marine and medical manufacturing
• predictably long tool life that minimizes unexpected failures and enhances
productivity by allowing machines to run optimal parameters longer
• high-quality material consistency to decrease blank inspection time and
speed up tool production with carbide rods that consistently meet
tight quality specifications
• extended tool life in demanding applications, reducing downtime,
cost per part and total cost of ownership
Carbide rod blanks in grade AM10F are available as solid rods in a variety of
finishes in imperial and metric dimensions.
further information: www.hyperionmt.com
AEROTECH.COM

materials & tools
New systems for milling, grooving
and parting off
Horn is expanding its DA milling system for corner,
face and plunge milling. With the DA65 type the
system offers a larger insert than the existing DA62.
This enables greater axial cutting depths during the
process.
Horn uses a six-edged indexable insert. The insert can be used
on both sides and has three axial and radial cutting edges
on each side. A large core cross-section with maximum insert
length is the impressive feature of the precision-sintered
triangular insert. Despite the negative insert angle, the insert
design results in a positive cutting geometry, which leads to
easy cutting. The six inserts per indexable insert result in a
good cost-per-cutting-edge ratio.
The DA65 system can be used as a roughing and finishing
system. In tests the milling system achieved surfaces during
finishing that meet market requirements. The choice of axial
and radial angles has been proven to result in lower torsional
moment and lower transverse load on the spindle compared
to previous systems. This allows the system to be used on
less powerful machines with unstable operating conditions.
Another advantage of the selected axial angle is the good chip
removal, especially in helical plunge operations.
The cutting edge geometry generates a precise 90 ° corner
angle with a maximum cutting depth of 7 mm (0.276''). The
patented indexable inserts are available with corner radii of
0.8 mm (0.031'') and 1.2 mm (0.047''). The proven SA4B carbide
substrate is suitable as an all-rounder for milling steel,
stainless steel, cast iron and aluminum. The inserts are also
available in the carbide grades SC6A and IG6B for machining
other material groups.
The tools are available as end mills in diameters of 32 mm
(1.260'') and 40 mm (1.575''). In these types they are equipped
with two or three inserts. The tools are available as shell
milling cutters with cutting diameters of 50 mm (1.969''),
63 mm (2.480''), 80 mm (3.150'') and 100 mm (3.937''). Depend -
ing on the diameter, there are four, five, seven, nine or
eleven teeth. All tools have targeted internal cooling to the
cutting zone. The DA65 milling system guarantees process
reliability across a wide range of applications, high expertise
and economic benefits for the user.
New system for grooving and parting off
S234 – this is the name of the newly developed parting system
that Horn has developed especially for large grooving
depths. The double-edged system enables a maximum depth
of cut of 33 mm (1.300''). This means that diameters up to
65 mm (2.560'') can be parted off reliably and economically.
The combination of high grooving depths, rigid clamping,
high-performance chip breaker geometry and internal cooling
makes the system extremely attractive in terms of price/
performance ratio.
S234 – this is the name of the newly developed parting system
that Horn has developed especially for large grooving depths
(HORN/Sauermann)
The inserts are available in cutting widths of 2 mm (0.079'')
and 3 mm (0.118''). The corner radii are 0.2 mm (0.008'') and
0.3 mm (0.012'') respectively. The sintered EN geometry ensures
reliable chip removal. Depending on the material to be
machined, the inserts are available in AS45 and IG65 grades.
Square shank holders in sizes 20 mm x 20 mm (0.787 x 0.787'')
and 25 mm x 25 mm (0.984 x 0.984'') ensure stable clamping.
Horn also offers reinforced grooving blades and tool holders
for the modular parting and grooving system. All types are
equipped with internal coolant supply.
further information: www.horn-group.com
10 no. 4, November 2025

materials & tools
Flexibility in a package
The EASYTap thread tap from LMT Tools combines
maximum performance with optimum costeffectiveness
and ease of use, making it an all-rounder
for reliable thread production in blind and through
holes.
This multi-talented tool is now also available in a set with
four different diameters – ideal for universal use in production.
One tool, many possibilities: the EASYTap is a true allrounder
and impresses in a wide range of machining tasks –
regardless of the type of hole, material or thread. It combines
performance, quality, functionality and cost-effectiveness in
one tool and provides a decisive competitive advantage.
Four times as strong: versatility as a quartet
The new tool set includes four different diameters – M6, M8,
M10 and M12 – providing a practical combination for various
applications. This reduces acquisition costs compared to individual
purchases and ensures optimized stocking in the
production process. Two versions are available – a tool set for
basic threads and a tool set for through threads.
Reliable thread tapping in any material
The EASYTap was developed with the key challenges in
thread production in mind and is characterized by perfect
chip removal, long tool life, a wide range of applications,
EASYTap set for through holes
and maximum process reliability. It produces true-to-gauge
threads up to 3xD and can be used in almost all materials –
steel, stainless steel, cast iron,or aluminum.
Optimized chip formation, low wear,
maximum service life
Manufactured from high-quality HSS-E material and refined
with a proven TiN coating, the EASYTap guarantees maximum
precision and durability. A newly developed cutting
geometry, optimized flutes and a 45 ° helix angle ensure
stable and efficient chip formation without chip buildup. The
uniform and low torque has a positive effect on tool life.
High performance meets
maximum cost-effectiveness
With EASYTap, LMT Tools has established a true all- rounder
for reliable thread production in blind and through holes.
Users benefit from excellent thread quality, fast machining
times, reduced tool changes and low costs per part. The new
tool set combines these strengths and expands them with
additional flexibility and a particularly economical solution
for universal use.
EASYTap set for blind holes
further information: www.lmt-tools.com
no. 4, November 2025
11

materials & tools
LACH DIAMANT ® – 100 Years
Tradition. Passion. Innovation.
part 14: How a mishap became a stroke of luck
for the birth of the »Dia-Monoblock« milling cutter
For the magazines “journal of hp tooling” and
“dihw” Horst Lach created two series:
“Poly – poly” and “LACH DIAMANT® – 100 Years”.
In these series he describes the transition into a
new era of material machining using PCD,
CBN, etc. up to the latest applications.
Horst Lach, born in 1940,
runs the company
LACH DIAMANT® – founded
in 1922 by Jakob Lach –
together with his son,
Dipl.-Ing. Robert Lach.
“He had a grin written all over his face” – you’ve surely come
across this expression in novels, used to describe a moment
of delight or amusement.
Reading the speech of our retiree Mr. Straube, quoted in
the last article (part 13), may well have brought such a grin
to your own face. His words, pointed and enriched with what
today are historic anecdotes, made vividly clear the difficulties
of establishing communication between East and West
Germany.
One example from his speech: the hours
of waiting at a post office in Saxony just to
make a phone call to Hanau – only to be
told, in despair, that the person he wanted
to reach was in a meeting and he should
try again later. Such anecdotes brought us
many smiles indeed.
Speaking of phone connections from
East to West, I am reminded of the Leipzig
Trade Fair, in fall 1990, where LACH
DIAMANT exhibited to demonstrate –
among other things – for the first time to
the East German furniture and woodwork
ing industries the sharpening of diamond
tools (PCD) on a LACH EDG sharpening
machine.
Apparently, to spare West German
exhi bitors the long waiting times Mr.
Straube had experienced at post offices,
the GDR provided 100 direct phone lines
to West Germany. Naturally, the LACH
DIAMANT trade fair team took advantage
of this opportunity.
To support communication, we purchased
the first “mobile phone” available
The first portable phone –
Philips Porty – helped us bridge
the communication gap
between East and West
on the market at the time – a portable Philips Porty, weighing
about 5.5 pounds. In our “dacha” in the evenings, before
falling asleep, we made a sport of repeatedly dialing
our loved ones’ numbers in the West, hoping that, after endless
ringing, someone would finally pick up. When that happened,
it meant we had successfully “captured” one of the 100
lines. That was our first short excursion into the lively founding
history of the LACH DIAMANT plant in Lichtenau near
Chemnitz.
Spark erosion made it possible
Some of the pioneering events that earned
LACH DIAMANT its role as a trailblazer
in German industry are already familiar
to you, dear reader, from earlier articles.
One was the discovery in 1978 of
spark erosion for cutting and profiling
polycrystalline diamonds (PCD). Without
this breakthrough, the development of
PCD cutting tools – essential to the success
of the wood/furniture industry, the automo
tive and aerospace industries, and later
wind power manufacturing – would not
have been possible in the 1980’s and 1990’s,
nor today.
Without spark erosion and the resulting
“EDG” grinding (Electrical Discharge
Grinding), LACH would never have become,
virtually overnight, a leading diamond
tool manufacturer for the superior
machining of wood and plastics. The founding
of LACH-SPEZIAL-WERK ZEUGE
GmbH in 1979 would not have happened
without this new technology.
But where did this sudden superiority
and know-how come from, leading to the
new company?
12 no. 4, November 2025

materials & tools
Leipzig Trade Fair, in fall 1990 – Konrad Wagner (†)
demonstrating natural diamond grinding
LACH DIAMANT »Dia-Monoblock« face milling cutter
in action
It had been just ten years since some toolmakers had committed
to carbide for machining wood-based materials. Now,
suddenly, a polycrystalline diamond cutting material appeared
that promised tool life 250 to 300 times greater than
carbide.
I still recall the LIGNA Trade Fair of 1979, the very first appearance
of LACH-SPEZIAL-WERKZEUGE GmbH, when
so-called “industry insiders” whispered behind their hands:
“Now Lach has lost his mind – he wants to machine wood with
diamond.”
Many helpers – and a colleague named chance
Yet the idea of Lach, the trained industrial businessman, was
not so crazy after all. First, it was based on the now-possible
processing and dividing of synthetic polycrystalline diamonds
by spark erosion (later known as »EDG-plus« sharpening
machines). Second, it relied on many helpers: Dieter
Claus, Gerhard Mai, Joachim and Andreas Weber, Kurt
Hemerka, Günter Hobohm, among others – a team combining
experienced LACH DIAMANT staff and new employees
at LACH-SPEZIAL-WERKZEUGE GmbH. True “pioneering
work” awaited every single member.
Today I know: such things don’t simply happen on their own.
They must be developed. And sometimes chance lends a helping
hand, leading to something new, as this example shows:
When LACH-SPEZIAL-WERKZEUGE GmbH turned its
attention to diamond tools for the wood and composite industries,
carbide toolmakers already knew that their carbide
milling cutters had very short lifespans. On an end profiler,
for instance, a carbide milling cutter might last only a single
shift. To speed up tool changes, base bodies were designed to
hold replaceable carbide inserts.
We thought: why not do the same – but with diamond?
Thus our »dreboquick®« system was born: base bodies
equipped with replaceable PCD cutting inserts instead of carbide.
But this path to superiority soon proved flawed.
»dreboquick®« diamond inserts – a great idea,
but unsuitable for base bodies with overly
generous tolerances
Users of the first base bodies equipped with »dreboquick®«
diamond inserts complained of unexplained scoring marks
on some »dreboquick®« inserts. Were our inserts imprecise?
No – the mystery was solved when we discovered the real culprit:
not our »dreboquick®« PCD inserts, but the base bodies
themselves. Originally designed for carbide inserts, they were
manufactured with tolerances far too wide for diamond.
no. 4, November 2025
13

materials & tools
Carbide inserts, prone to scoring as well,
could “wear in” after a few meters of use
and then run smoothly. Diamond, however,
allowed no such forgiveness.
This realization led to a new approach: if
base bodies designed for carbide inserts were
unsuitable, we would have to take another
path. And thus the »monoblock diamond
milling cutter« was born.
In this design, each PCD cutting edge is
soldered tooth by tooth directly into the base
body, creating a unified »monoblock milling
cutter«. Originally conceived for machining
composite materials in the woodworking and
furniture industries, the LACH DIAMANT
»monoblock« would, starting in the mid-
1990s, reach new heights in automotive applications
as well.
Booming demand
After the first presentation of the diamond
tool program at LIGNA 1979 – modeled on
the then-current carbide program – demand
for the superior »monoblock diamond milling
cutters« exploded. Word spread quickly
that with the new »diamond monoblock milling
cutter« the tedious task of changing carbide
inserts after every shift was a thing of the
»Dia-Monoblock« milling cutter with patented
»Cool-Injection« – coolant directed through a
bored diamond cutting edge
past. The triumph of diamond tools in the wood, furniture and composite
industries had begun.
And it was not just the tools. At the same time, machine builders and
CNC developers were preparing to leap from NC technology to multi-axis
CNC machines for mass production. The wood and plastics industries thus
became forerunners to the automotive sector.
By the late 1980’s and early 1990’s things had balanced out again. Many
CNC machines originally developed for the wood industry could now be
used to machine aluminum, for example.
Once more it was diamond milling cutters – developed out of necessity,
with soldered rather than clamped cutting edges, and with a deep understanding
of the material – that led the way.
Years later, under the engineering leadership of Mr. Eugen Maurer, the
»dia-compact« milling cutter entered service on a production line at
Audi’s engine plant in Hungary: a 63 mm »Dia-Monoblock milling cutter«
equipped with 16 cutting edges (Z=16), each 12 mm long. The development
of the »Dia-Monoblock«, rightly dubbed »dia-compact«, continued apace.
Proven and established
Out of curiosity, I recently typed “Monoblock milling cutter” into Google –
and was amazed to see how many LACH designs have found their way onto
the world wide web: from the »Dia-Monoblock« for HSC/HPC aluminum
machining, to »Cool-Injection« and »Cool-Injection-Plus« models, with
coolant delivered directly through PCD cutting edges, to chip deflectors. All
»Dia-Monoblock milling cutters« are fully assembled, balanced, and supplied
with the adapter of choice – ready to use without adjustment.
Award-worthy 0 63 mm »Dia-Monoblock«
milling cutter with 16 PCD edges – no
tighter configuration possible
In the next article you will read more about what else unfolded at
LACH DIAMANT during the 1980’s.
Horst Lach
further information: www.lach-diamond.com
14 no. 4, November 2025

New replaceable head drilling system
materials & tools
With the BT 800 Gühring is launching a highperformance
replaceable head drilling system with bayonet
lock, which is particularly impressive in medium
to large diameters from Ø 14 mm due to its costeffectiveness,
flexibility and tool life.
When it comes to cost per part, every single parameter
counts: tool costs, set-up times and process reliability determine
the efficiency of production. With the new BT 800
replaceable head drilling system, Gühring addresses precisely
these points – and offers an economical and highperformance
alternative to conventional solid carbide drills.
Modular system with solid carbide performance
The BT 800 combines two properties that are often mutually
exclusive: the wear resistance of a solid carbide tool with the
modular flexibility of a replaceable head system. The innovative
bayonet interface is the centerpiece of the BT 800 standing
for maximum clamping force, precision and repeat accuracy.
Whether material change, component variation or process
optimization: with its modular design the BT 800 can be
quickly and easily adapted by changing the drill head directly
in the machine without removing the carrier.
Cost efficiency for large diameters
The system fully utilizes its economic advantages, especially
for diameters from Ø 14 mm. Only the drill head is replaced
when worn – this not only lowers tool costs, but also reduces
warehousing and capital commitment.
Focus on productivity and flexibility
The option of combining different drill heads on one carrier
shaft ensures a high degree of flexibility for changing requirements
and materials. Heads can be changed quickly and
safely – an advantage that reduces set-up times and increases
machine availability.
Another plus point: Gühring offers a closed tool cycle for
the BT 800, including regrinding (up to twice) and a recycling
service. This not only reduces costs but also conserves
resources.
Program and technical features
This modular system was launched in June 2025 with two
holders for the Ø range 16.00 - 26.00 mm for drilling depths
of 3xD and 5xD. Narrowly stepped Ø steps (in 0.1 mm increments)
enable good guidance and increase the stability of the
tool. The drill head with Persistum coating was specially developed
for steel machining in the Ø range 16.00 - 26.00 mm.
The range will be expanded in autumn 2025 with holder
sizes 1.5xD, 8xD and 12xD as well as a Pilotier drill head with
internal cooling for 4-fold cooling.
further information: www.guehring.com
Productivity at the highest level
With the Drion·tec® E-Peak D5150 Walter is introducing
a new replaceable head drill that represents
the “peak of productivity” when drilling from solid.
According to Walter, the D5150 enables enormously
high feed rates and metal removal rates, which significantly
reduces the cost per hole. Pilot drilling is not
required – and the replaceable head (DS50) can be
exchanged directly in the machine without screws.
Both of these features reduce machining and set-up times.
The drill body of the D5150 has reinforced radial contact
points and inclined axial contact surfaces that ideally absorb
any occuring cutting forces. The three-dimensional flute geometry
with a large axis angle, in combination with a powerful
internal coolant, enables efficient, reliable chip evacuation
even with inclined or curved workpiece surfaces.
In addition to high productivity, the replaceable head drill
impresses with its high process reliability. This comes from
the stable, patented cutting point design with axial pullout
protection. It ensures risk-free retracting and retains its
release torque even after numerous head changes. The lowvibration
DS50 interchangeable heads guarantee excellent
Walter replaceable head drill Drion·tec® E-Peak D5150
centering and drilling quality thanks to their free grinding
and point angle. Thanks to its universal M geometry and two
cutting material grades (WPP35 and WMS35), the D5150 can
be used with a wide cutting data window in all ISO material
groups P, M and S, as well as in K, N and H. Customization is
simple via “plug & play” with the recommended parameters.
The D5150 is initially launched with Ø 9-17.99 mm (including
inch nominal diameters), and in drilling depths of 3×D, 5×D
and 8×D. Several head dimensions can be used in the same
drill body, thereby reducing storage and purchasing costs.
further information: www.walter-tools.com
no. 4, November 2025
15

news & facts
Turnkey solution with 78 tools
Collaboration between CHIRON Group and MAPAL in the US
In a factory in Charlotte, North Carolina, CHIRON
America Inc. assembles turnkey solutions based on
standard machines supplied by their German parent
company in Tuttlingen. These solutions are customized
to meet the specific needs of their customers.
Once again MAPAL was selected as partner and tool
supplier for a CHIRON machine used in truck parts
production.
The CHIRON Group has been active in the United States since
1993, with a modern factory opening in Charlotte in 2001.
The 7,000 m 2 plant employs 100 employees focused on adapting
German-built machines to meet the needs of the American
industry. From fine-tuning hydraulic systems to developing
advanced automation and turnkey solutions, the focus
is on delivering precision and efficiency. These machines
are designed for production of specific components and are
delivered to customers fully equipped with software, clamping
fixtures and tools – ready for immediate operation.
Customer proximity is key
Like CHIRON Group, MAPAL also operates in the United
States with two sites located in Port Huron, Michigan and
Fountain Inn, South Carolina. The precision tool makers
and technology partners from Aalen/Germany recognized
at an early stage that customer proximity was essential in
the American market. This insight led to the establishment
of MAPAL’s first international subsidiary in 1977. It began
in New Jersey with the reconditioning of MAPAL tools. As
MAPAL expanded into the automotive industry in the following
years, business grew significantly. It soon became
clear that the small factory was no longer sufficient. The next
logical step involved setting up a manufacturing site closer
Two of the 800 x 800 mm components can be machined
simultaneously on the DZ 25 P five-axis from CHIRON Group
The CHIRON Group team with two MAPAL employees (l. to r.):
J. Morado (apprentice), K. Loyst (application engineer),
J. Korolev (marketing and communications), M. Hipp (head of
application engineering), J. Flores (lead project engineer),
P. Reich (director of operations), M. Beerhalter (global project
engineer MAPAL) and S. Anderson (sales engineer MAPAL)
to key automotive customers. MAPAL opened its production
site in Port Huron in 1995 with a focus on manufacturing
and reconditioning of high-precision tooling, such as reamers
with guide pads. Through its proximity to Detroit the company
was able to provide faster response times and comprehensive
technical support to customers.
By consolidating technical knowledge within its international
centers of competence, MAPAL expanded its knowhow
and expertise in the manufacturing sector. In 2019 the
precision tool maker expanded further by opening a second
factory in the southern region. The Fountain Inn site enhanced
sales, service and manufacturing capabilities, complemented
by a state-of-the-art aerospace test center. Today
MAPAL Inc. manufactures solid carbide and PCD tools
at both sites using technology and processes that adhere to
the MAPAL Group’s global standards. The tools include
drills with one or more diameters, form cutters, reamers and
tools for composite machining – all of which are also reconditioned
in-house.
CHIRON Group and MAPAL have been cooperating in
North America for nearly as long as the machine tool builder
has been present in the region. As a trusted OEM supplier,
MAPAL has supported CHIRON Group’s work across the
automotive, aerospace and medical technology industries, as
well as their suppliers. “To offer our customers the best solutions
we need reliable partners – a quality MAPAL has consistently
demonstrated”, says Jesus Flores, lead project engineer
at CHIRON Group in Charlotte.
Demanding components
In the most recent project, MAPAL provided a complete
solution for a truck manufacturer, supplying all the tools
and process design. The component being produced is the
front transmission housing for a large truck diesel engine. To
ensure a smooth start, MAPAL supported the customer with
on-site run-off support and expedited optimized tools, keeping
the project on track from day one.
16 no. 4, November 2025

news & facts
The
double-spindle machining center DZ 25 P
five-axis has been developed by CHIRON Group for highly
productive machining of components with large-scale production
This highly complex component with many bores and a
complicated form is machined out of aluminum A380 diecasting
alloy. The customer aims to produce 120,000 units per
year. With a potential production run of six to eight years,
the total number of units could reach a million before a
design modification may occur.
Efficient manufacturing is key to produce the required
production volume of transmission housings. The doublespindle
machining center DZ 25 P five-axis has been selected
for this task, which CHIRON Group has developed especially
for the productive machining of components with large volumes.
Its rigid structure allows for high axis acceleration and
rapid traverse speeds, ensuring dynamic and precise machining.
In the spacious working area the machine can process
two 800 x 800 mm components simultaneously. In the first
step the workpiece is clamped in its delivered state in order to
perform pre-machining, which helps release internal stresses
within the component. At the same time machining with
midrange tolerance requirements takes place. The precision
machining of fitting bores and surfaces relative to reference
points happens in a subsequent clamping step.
Two-thirds custom tools
The tools supplied by MAPAL play a key role. 78 tools have
been provided, with two-thirds being custom-made and
A PCD-tipped custom tool is used to pre-machine
a deep blind bore
CHIRON America Inc. has a modern factory in
Charlotte since 2001
precisely designed to the corresponding machining step with
special geometries and dimensions. In many cases, the complexity
of the tools is a direct result of the component design
or the selected machining strategy. Among them, 33 of the
tools are PCD tools, while the remaining 45 use carbide cutting
edges.
Whenever possible multiple machining steps have been
combined into a single tool, allowing the machining of various
diameters in one operation. “Cycle times are reduced
with these custom tools”, explains Jesus Flores. “In this
way, we save multiple tool changes every time, which improves
both the machining times and precision.” Besides
speed the components require a high level of precision and
quality that surpass typical automotive industry standards.
When it comes to positioning accuracy, a tolerance of 25 µm
has been prescribed for diameter tolerances ranging from
8 to 10 µm. “This component has some of the highest quality
requirements that I’ve ever seen. That’s a challenge for
a workpiece of this size”, says Flores. The combination of cutting-edge
machines and high-performance MAPAL tools
has made the project a success. CHIRON Group highlights
the quality of the PCD tools in particular, which are ideal
for long production runs due to their extreme resilience and
hardness.
Proactive support
CHIRON is satisfied with the results of its collaboration with
MAPAL: “The quality of the tools is excellent. Their performance
meets our requirements perfectly.” The support
CHIRON Group has received in Charlotte since its collaboration
with MAPAL began has made a significant impact.
According to CHIRON, MAPAL’s tool design and application
support have been outstanding. The proactive approach to
collaboration has also played a key role. MAPAL consistently
does more than just provide tools by offering tailored solutions
and timely support whenever it is needed.
MAPAL has also praised the excellent teamwork. “I’m very
proud of the collaboration, which has made it possible to
deliver this large tool package within the tight deadlines
prescribed by the customer”, says Evan Osantoski, sales
and application engineer in Michigan. From project launch
to customer handover, the process took just eight months.
CHIRON Group and MAPAL want to continue to cooperate
in the US and already have the next project in the
pipeline.
further information: www.mapal.com
no. 4, November 2025
17

news & facts
Global sales and service network for
multi-spindle machines expanded
Schwäbische Werkzeugmaschinen GmbH (SW) has
further expanded its global footprint with the opening
of a new subsidiary in Pune, India, effective April 1,
2025.
This move strengthens SW’s presence in the local market
and enables customers to benefit even more quickly from the
company’s advanced manufacturing solutions.
The newly established subsidiary, Schwaebische
Werkzeugmaschinen India Private Limited, led by Rakesh
Patel, will handle sales and service for the company’s stateof-the-art
CNC machining centers and automation solutions.
For the past 18 years SW has successfully operated in India
through local representatives. Establishing the subsidiary
marks a strategic step toward enhancing customer proximity
by relying on local expertise. “Globalization is part of our
everyday operations at SW. ‘Think globally, act locally’ is
a cornerstone of our international market strategy”, says
Dr. Daniel Rieser, managing director of sales and marketing
at SW. “Having direct access to our customers is absolutely
essential. This requires reliable business partnerships and a
strong local service team.”
Strategic growth market India
The subsidiary is the next logical step for the company, providing
its Indian customers with service and sales in their
home country. According to Rieser, India’s high level of
industrialization and increasing demand for advanced
manufacturing technologies make it a key market for the
SW Group. Pune was chosen deliberately as the location
for the new site: the city is rapidly developing into a hub for
industrial parks, hosts a wide range of suppliers and manufacturing
companies, and offers both a growing infrastructure
and a large pool of highly skilled professionals.
further information: www.sw-machines.com
Investment in automation specialist Sirio srl
Bold steps in turbulent times: following the acquisition
of Italian automation specialist Carmet in 2023,
the IMA Schelling Group is currently expanding its
presence in Italy and acquiring shares in Sirio srl,
Treviso.
The investment is another building block in a long-term
strategy to secure and further develop the Italian market for
IMA Schelling.
The agreement provides for a gradual takeover. The initial
step will be a minority stake, with full integration planned
by 2028. “Sirio has established itself over the past decades
as a specialist in automation solutions for mechanical and
plant engineering”, explains Maximilian Lehner, managing
director at IMA Schelling. “IMA Schelling and Sirio have a
long history together. On this basis we now want to ensure a
stable transition that opens up future prospects for both
companies.”
Together with Carmet and its own service subsidiary
IMA Schelling Italia, in the future a triad will be created that
will significantly strengthen IMA Schelling’s market position
in southern Europe. The integration of Sirio will primarily
cover the area of batch size 1 systems – a segment that
the group of companies wants to secure strategically.
“Despite the tense situation in the industry we want to initiate
change”, emphasises Maximilian Lehner. “With our investment
in automation specialist Sirio we are strengthening
structures, service and project expertise directly on site.
Customers in Italy will benefit from shorter distances and
even better support.’
With Sirio, Carmet and IMA Schelling Italia, the IMA
Schelling Group is further expanding its international network.
The path is clear: investment in highly relevant markets,
stronger regional roots and the expansion of strategic
partnerships. By 2030 the group aims to further strengthen
its market position and tap into new areas of growth.
further information: www.imaschelling.com
18 no. 4, November 2025

Humanoid robots: “vision and reality”
Paper published by IFR
news & facts
Neura Robotics
Humanoids are considered to be the next big thing in
robotics: China, the world’s largest market for industrial
robots, has set out specific targets for its plans to
mass-produce humanoids.
Meanwhile, tech companies in the US and Europe are
announc ing significant funding. The vision is to create generalpurpose
robots based on human motion mechanics. What
are the trends, opportunities and potential limitations of humanoids?
The International Federation of Robotics has released
a new positioning paper that provides valuable insights.
“Futuristic humanoids working in homes, businesses
and public spaces fuel people’s interest”, says Takayuki Ito,
president of the International Federation of Robotics. “Since
our environment is optimized for the human body the
demand for a quick, universal helper to maintain manufacturing
and services is evident. If and when a mass adoption
of humanoids will take place remains uncertain. In any case,
humanoids are not expected to replace the types of robots
currently on the market in the future. Instead they will complement
and expand upon existing technology.”
Humanoid adoption by region
In the United States, tech companies like NVIDIA, Amazon
and Tesla are heavily developing advanced AI and robotics
technologies. Besides military funding, a lot of private investments
support this development and result in a large number
of start-ups developing humanoid robots. There is a strong
interest in using humanoids in logistics and manufacturing.
These machines are seen as tools for enhancing productivity
and efficiency rather than as social companions. The focus is
more on practical applications and less on integrating robots
into daily social life.
China put humanoids in the center of their national strategy.
The government wants to showcase its competences and
global competitiveness in this field of technology. There is a
strong emphasis on using humanoids in the service sectors,
such as customer service. The use in manufacturing to
automate production lines and reduce reliance on human
labor seems only a second step. One key element of the
Chinese strategy is to establish a supply chain for key components
that is scalable.
Japan has been a pioneer in the development of hu manoid
robots with Honda’s Asimo being an early example unveiled
in October 2000. Robots are regarded as companions rather
than mere tools. Humanoid robots such as Pepper and
Palro are designed primarily as social robots and are used in
educational settings, commercial stores and elderly care facilities.
This reflects the needs of Japan’s ageing society. The
focus is on creating robots that can live harmoniously with
humans and are accepted as part of society. Leading companies
such as Kawasaki are developing humanoid robots as
research platforms.
Europe places a strong emphasis on the ethical implications
of robotics and AI. Europe has a significant focus on
collaborative robots that work alongside humans in industrial
settings. The focus is on enhancing safety, efficiency and
human capabilities, rather than on replacing human workers.
The focus is on human-centric design and the social and
societal impact of robots. European businesses are more cautious
about the use of humanoids to meet the automation
needs of the manufacturing and service sectors in the short
to medium term.
Outlook
Thanks to their human-like dexterity and adaptability,
humanoids are well placed to automate complex tasks with
which current robots struggle using traditional programming
methods. However, mass adoption as universal household
helpers may not happen in the near or medium term.
further information: www.ifr.org
no. 4, November 2025
19

news & facts
DN Solutions accelerates “Vision 2032”
DN Solutions, the world’s third-largest and Korea’s
leading machine tool company, announced at EMO
Hannover 2025 the key achievements and future direction
of its global growth strategy: “Vision 2032”.
The strategy – to become a Global Technology-based TOP
manu facturing solutions leader – is well on track for accelerated
completion.
“Since the company’s founding in 1976 we’ve surpassed
300,000 machines deployed globally. DN Solutions has established
itself as a trusted partner for diverse industries worldwide,
including in Europe”, said Won-jong Kim, CEO of DN
Solutions. “Through strategic partnerships and local investments
we will continue to expand our technological leadership
and global footprint, delivering the most advanced
products and services to customers worldwide.”
Key milestones in the past two years
• expanded installed base:
since the company’s founding in 1976,
DN Solutions has surpassed the milestone of
300,000 machines deployed globally, significantly
growing its market share in major countries
• industry diversification:
the company rapidly expanded beyond the
automotive and semiconductor sectors into
aerospace, space and defense
• advanced technology leadership:
DN Solutions has demonstrated its commitment
to innovation by launching the DLX series for
PBF additive manufacturing and making an
equity investment in carbon black to lead the
development of manufacturing AI
• global footprint:
to strengthen its global presence, the company
stabilized its German R&D center, began
construction of a new plant and R&D center
in India and opened a new tech center
in Chicago, U.S.
DN Solutions
Since its founding in 1976, DN Solutions has established
itself as a leading global machine tool company, offering
around 400 product types, including advanced turning and
milling technologies. By revenue, DN Solutions ranks as the
world’s third-largest machine tool brand. With a network of
more than 140 dealers in 66 countries, the company meets
the diverse needs of customers across industries such as
automotive, aerospace, medical technology, energy technology,
semiconductors & electronics, and construction technology.
Won-Jong Kim, president & CEO DN Solutions:
“Europe is pivotal to DN Solutions’ future growth.
We’re expanding our capabilities in Europe by opening
new facilities and enhancing local talent. Looking ahead,
we aim to solidify our position as a market leader,
driving innovation and excellence across the continent.”
HELLER acquisition: a new chapter in Europe
On August 26, DN Solutions signed an agreement in
Nürtingen, Germany, to acquire 100 % of HELLER Holding’s
shares. The transaction, pending regulatory approval, is
projected to create a combined entity with revenues of
approximately EUR 2 billion.
Kim reaffirmed the company’s commitment to honor all
existing and new contracts, ensuring uninterrupted customer
support. He also pledged to retain HELLER’s management
team and key talent to preserve the technical expertise and
customer trust built over its 130-year history.
“The heritage, management philosophy and technological
excellence HELLER has built will remain at the heart of its
operations”, Kim said. “Together DN Solutions and HELLER
will function as a ‘One Team,’ building stronger partnerships
across German and European industries.”
Delivering enhanced value to
European manufacturing
Through the HELLER acquisition DN Solutions aims to
significantly contribute to the revitalization of the German
machine tool sector, offering European customers a true onestop
manufacturing solutions platform. Both organizations
will leverage the stronger financial foundation and global
economies of scale to build a more resilient supply chain
and integrate advanced IT capabilities for smart machine
tools. These efforts will ultimately enhance the competitiveness
of European manufacturing and deliver greater value to
customers.
further information: www.dn-solutions.com
20 no. 4, November 2025

news & facts
Quite a story
A family, three generations
and a history of technology
and innovation that
began 75 years ago in a
small shop near Piazza San
Marco in Venice. A journey
that continues and intends
to sail full steam ahead towards
new, increasingly ambitious goals.
This is the story of Sorma, a company that took its first steps
in 1950, founded by Alberico Sorgato and Zoe Marano, visionary
entrepreneurs who started marketing diamond tools for
the artistic Murano glass industry: a unique product, fragile
and precious like the city where it was born, which requires
excellent thought and tools. And perhaps it is precisely from
here that the values of care, respect and the pursuit of quality,
that still permeate the company today, were born.
Quality and service drive growth
75 years have passed since then, and that small reality has
been radically transformed, becoming a solid company
with an international outlook, guided by the heirs of the
same family that founded it. Over the years the company
has carved out the role of an innovative protagonist in the
field of abrasive tools and, thanks to the experience it has
gained, today the Sorma name is synonymous with the
highest quality and service in the field of high-tech diamond
tools. It has focused its attention on the most innovative applications
of flexible diamond abrasives, playing a leading
role in their introduction to the world market in 1980. Year
after year and generation after generation, by listening to the
market and its needs, Sorma has expanded its offer over the
years: from solutions for glass processing it extends to superabrasive
tools specific for the processing of stone, metal and
composite materials.
Following its industrial vocation, superabrasive tools
were subsequently joined by cutting tools for the metalworking
industry. It is precisely in this last market that the
company began important and long-lasting collaborations
with leading brands such as Yamawa, Kyocera, LMT and
Kemmer, joined over the time by its proprietary lines, Osawa
and Nikko Tools.
Today Sorma, whose headquarters are in Mestre, operates
in 60 countries and relies on the support of around one
hundred employees including commercial and administrative
staff, logistics and sales force. Not far from Mestre is the
4,000 m 2 modern Sorma logistics center, located in Marcon
(VE), in a strategic position a few km from Marco Polo airport
in Venice. The logistics center is equipped with a clean
energy production plant to minimize its environmental
impact and features a 100 % automated system for the reduction
of error margins to a minimum and greater efficiency
in picking and shipping goods.
Diamond tools take
center stage
Sorma tools are produced using
different technologies: electrodeposition,
resinoid bond, vacu um
brazing and metal sintering; they
are available in the form of rigid
tools and in the form of flexible abrasives
to ensure high performance on most
materials used by modern industry, including the hardest
and most difficult to work with.
The offer covers diamond tools for the processing of
natural stones, coating ceramics and construction materials
in general, used on stationary machines such as bridge cutters,
edge polishers, machining centers, but also for finishing
operations with portable machines.
Diamond products like the Diahard XT, Fastline or the
Diaface allow for precision machining with high stock removal
on glass materials such as float glass, laminated glass,
mirrors, crystal, artistic and scientific glass. Sorma is also a
key player in the mechanical industry with a wide range of
abrasive and superabrasive tools for the finishing and superfinishing
of metals. For example, the company provides solutions
for the aerospace and energy industries, intended for
machining components that are particularly resistant to corrosion,
wear and high temperatures, made of carbide or with
coatings such as the HVOF (High-velocity oxygen fuel).
The strength of a group
Thanks to a widespread distribution based on a network of
qualified resellers, Sorma has been able to build a corporate
culture over the years based on listening to the needs of
users, managing to integrate its range with products aimed
at new processes or new materials.
This culture of listening contributes every day to giving
substance to its vision which relies on the centrality of the
person, on respect and on the desire to work together as
unique individuals within a small community: today, as then,
these values take on an increasingly strong meaning which
are reflected in its way of operating and presenting itself on
the market. Sorma promotes a business model based on sustainable
growth shared with its commercial partners, distribution
network and customers. The arrival of the three subsidiaries
to support its activity in Europe – Sorma Bema
France (founded in 2016), Sorma Ibérica (2023) and the
newly born Sorma Deutschland (2024) – testifies to the daily
commitment of a company which, in these first 75 years,
has evolved by becoming a solid group that has been able to
seize the challenges of the markets in which it operates without
losing its family dimension, where employees, customers,
and production partners are at the center of its work.
further information: www.sorma.net
no. 4, November 2025
21

news & facts
fairs
IMTEX 2027
Indian Machine Tool Manufacturers’ Association (IMTMA) is ready
to organize the next edition of its flagship event, IMTEX. The exhibition,
which is South and South East Asia’s largest exhibition
dedicated to metal cutting and manufacturing technologies, will be
held at Bangalore International Exhibition Centre (BIEC), Bengaluru,
January 21 to 27, 2027. Tooltech and Digital Manufacturing will run
as concurrent events.
IMTEX, first organized in 1969 at Vikhroli, Mumbai, has a history of over
50 years in demonstrating every evolution in metalworking technology to
help manufacturers innovate, adapt and stay relevant to customers. The
exhibition brings diverse groups of stakeholders on a common platform to
share knowledge and do business transactions.
Reminiscing about the exhibition that is nearing six decades, Rajendra S.
Rajamane, president – IMTMA, stated, “Indian machine tool industry has
been growing steadily, with production in FY 2024-25 estimated to have
increased by 7 % to reach 214,566 crores (around US $ 1.7 billion), while consumption
is projected to have risen by 17 % to reach 831,781 crores (around
US $ 3.7 billion). IMTEX 2027 will further
boost this growth as the exhibition provides
an ideal platform for companies to launch
new products and showcase technological
advancements through live machines for
various industries.”
Echoing this sentiment, Jibak Dasgupta,
director general & CEO of IMTMA, stated,
“The previous edition of IMTEX held in
January 2025 attracted 1,100 exhibitors from
23 countries and 1,33,166 visitors from 70
nations was a grand success with a tremendous
business impact.
IMTEX 2027 will be positioned as
even bigger and lead the way for more
developments.”
further information: www.imtex.in
EMO MILANO 2027:
A journey to the center of innovation
After the German edition, took place these days in Hanover, EMO,
the world exhibition dedicated to the metalworking sector, will
return to Italy in 2027.
The organization of the event is entrusted to the operational structures of
UCIMU-SISTEMI PER PRODURRE, the Italian machine tools, robots and
automation systems manufacturers’ association. EMO MILANO 2027 will
be held at the fieramilano exhibition center October 4 to 8, 2027.
Promoted by CECIMO, the European Association of Manufacturing
Technologies, and organized by EFIM-ENTE FIERE ITALIANE MACCHINE,
the event, which is alternately held in Hanover and Milan, will thus return to
Italy after six years.
Indeed, it was in 2021 when, despite the pandemic, the organizers of EMO
MILANO 2021 succeeded in attracting 60,000 operators from those countries
that had given the green light to travel from their territories. Even in
that peculiar situation, the figure confirmed the appeal of the event and of
the city of Milan, surely central and undoubtedly one of the best served and
connected by international and intercontinental transport systems. After all,
the previous edition, in 2015, was a real success considering the number of
exhibitors and visitors, setting an all-time record for the Milan edition of
the world trade show, both in terms of number of participants and square
meters occupied.
The next edition is expected to be rich in content and opportunities for the
operators of the sector: EMO MILANO 2027 will propose a real “journey to
the center of innovation”, as stated in the slogan chosen to accompany the
event communication from now until 2027.
At EMO MILANO 2027 the entire spectrum of international products
from the sector will be on display: metal cutting and metal forming machine
tools, robots, automation systems, additive manufacturing, digital solutions,
artificial intelligence. These are technologies on which the sustainable
development of the planet depends, a theme
that will be widely covered by the exhibition.
Special attention will be devoted to the
organization of the event which, given the industrial
development expected in the coming
years and the attractiveness of the city of
Milan, is anticipated to be a sell-out fair.
For this reason, the organizers of EMO
MILANO 2027 have reserved all 12 exhibition
halls available for the trade show.
further information: www.emo-milano.com
22 no. 4, November 2025

fairs
news & facts
Securing the future of machine tools
in a changing landscape
EMO 2025 became a stage for unity as machine tool
associations from across the globe came together to
highlight the sector’s critical role in shaping the future
of manufacturing. Despite facing a geopolitical uncertainty
and economic challenges, EMO 2025 showcased
the machine tool sector’s capacity to adapt and
to innovate. Facing diverse conditions in 2024 and
2025, industry representatives stressed that continued
progress would rely heavily on joint initiatives, creative
solutions, and flexible strategies to ensure longterm
growth.
CECIMO Group speakers
“Despite regional differences we share common goals: creating
a better business environment, expanding global markets,
tackling skills shortages and driving innovation through
green and digital technologies.” Highlighted Mr François
Duval, CECIMO’s president, in his opening remarks at
the CECIMO’s press conference at EMO Hannover 2025, as
representatives of the Indian, American and Japanese machine
tools’ sector were present during the event.
Mr. Marcus Burton, chairman of CECIMO’s economic
committee, presented key insights on the machine tool market
that were produced with the strong cooperation of the
National Associations organized by CECIMO. Mr Burton
underlined how European machine tools (MT) production
decreased by 9.2 % to 25.1 billion EUR in 2024 from 2023.
Recent projections estimate a further decline of around
8.6 % in 2025 compared to 2024. Because of this estimation,
the world share of European MT production is predicted to
drop to 31.5 % in 2025 (compared to 34 % in 2024). Looking
at consumption levels, CECIMO countries witnessed a 16 %
decrease in consumption in 2024, and projections point to a
further drop of around 3.6 % in 2025.
The order trend for the CECIMO 8 countries has reflected
the economic challenges, the results for Q2 2025 shows a
decrease of 2 % quarter on quarter. However the CECIMO 8
order index was 6 % YoY higher than in Q2 2024 based on
improving foreign orders. In his concluding remarks Mr.
Burton highlighted that “even though the results for the last
two years represent a negative outlook heavily impacted by
geopolitical, trade and economic uncertainties, the year
ahead (2026) is expected to deliver stronger results driven by
the anticipated increase in order and consumption levels”.
In reference to the Japanese machine tools sector
Mr. Kazuo Yuhara, president of Japan’s Machine Tool Builders’
Association (JMTBA), pointed out how “domestic demand
decreased by 7.4 % compared to the previous years and how
overseas demand increased by 3.4 %”. He presented how
production of metal cutting machine tools shrank by 14.3 %
from previous year in 2024, accounting around 901.3 billion
yen, below 1,000 billion yen for the first time in three years.
In addition a decline in overall trade data has been recorded
regarding export and import of metal cutting machine tools.
As a matter of fact, export data was 8.3 % down from previous
year while import levels went down by 11.5 % in 2024. To
conclude, Mr Yuhara highlighted the mixed results registered
by the initial forecast for 2025 and the current situation.
The initial forecast for 2025 projected strong order activity. In
the first half of the year, total orders and exports rose yearon-year,
while imports declined.
During his presentation, Mr. Douglas K. Woods, president
of AMT – the Association for Manufacturing Technology
in the USA, emphasized the strong domestic consumption
growth in 2024 compared to 2023 (an expected increase of
around 12 %). Mr. Woods highlighted how this surge is mainly
driven by increase demand across aerospace, defense, the
reshoring of influenced sectors and by the impact of foreign
direct investment. Looking ahead to 2026, AMT expects a
stable environment (even though a slight decline in orders is
expected). For instance, Mr Woods pointed out how: “the observed
softness likely reflects greater caution due to elevated
financing costs, uncertainty over trade policy, persistent geopolitical
risks and a potential saturation effect after several
years of sustained investment”.
Regarding the Indian MT sector, Mr. Jibak Dasgupta,
director general & CEO of the Indian Machine Tool Manufacturers’
Association (IMTMA) highlighted the increasing
importance of India. For instance, the Indian expansion
can be observed by its GDP, reaching $ 4.19 trillion in current
prices, recording 6.5 % real GDP growth in FY 2024-25,
and how it is projected to grow at the same pace until 2029.
Mr. Dasgupta described the remarkable growth of the
Indian machine tool industry with a total consumption of
$ 3.7 billion in FY 2024-25. ”The automotive and auto component
sector is currently the leading consumer, accounting
for nearly 50 % of the demand. However sectors like general
engineering, die & mould, construction and farm equipment
remain significant MT purchasing sectors.” During the presentation
was also presented Indian’s industrial growth and
the support of the government initiatives. To conclude, Mr
Dasgupta pointed out the opportunities that India represents
in terms of international collaboration and investments.
further information: www.cecimo.eu
no. 4, November 2025
23

processes
Quality and efficiency for internal gears
SkiveFinishing® is a new method for efficiently hard
machining high quality internal gears. It combines the
flexibility of gear skiving with the surface quality of
CBN grinding technology. An innovative CBN tool by
Liebherr-Verzahntechnik GmbH ensures a long tool life
and even enables profile modification.
Up to now two methods have been used in hard-fine machining
internal gears. Firstly, hard skiving with a geometrically
defined cutting edge, which – while economical – comes up
against its limits when maximum quality is required. Secondly,
profile grinding with a geometrically undefined cutting
edge, which offers maximum precision, but is time and cost
intensive and therefore only suitable for series production under
certain limited conditions, for example in e-mobil ity or
commercial vehicles. SkiveFinishing® fills this gap: it uses the
kinematics of gear skiving in combination with a non-dressable
electro-plated skiving tool. This achieves higher quality
than in hard skiving, but is also faster and more efficient than
profile grinding.
Innovative tool, tested technology
The CBN tool used offers a crowned geometry and multiple
usable shift positions. It machines with an axial feed along
the contact line. If a position is worn, the tool shifts to the
next position. The tool design and the extremely tough CBN
coating (the second hardest cutting material after diamond)
combine to ensure a long tool life and high process stability.
“SkiveFinishing® combines the flexibility of skiving with the
advantages of CBN grinding”, explains Haider Arroum, division
and site manager, tools. “This means optimal roughness
values and efficient processes can be implemented by specific
selection of CBN grain sizes.”
Non-dressable, electro-plated skiving tool with
multiple shift positions
Component modifications possible
SkiveFinishing® increases the tooth flank load capacity
thanks to the higher residual compressive stresses. Modifications
like tip reliefs, profile crowning or tooth trace modifications
can also be made directly to the component – even
on challenging geometries like internal gears. Previously this
was only possible using the costly profile grinding process
or a special dressing kinematic process.
If the tool is completely worn, it will be treated at the
Ettlingen site. Liebherr’s CBN expertise goes back more than
30 years and so guarantees consistently high quality. “This
opens up new options for users to optimally adapt manufacturing
process to components and economic efficiency”, adds
Haider Arroum.
High quality in cost-effective machining
SkiveFinishing® is aimed at applications which have to combine
very high quality requirements with economically efficient
processes. In aerospace, where cost pressures are constantly
rising, precision and load capacity matter. In e-mobility,
new gearbox designs require lower noise levels and longer
service life. SkiveFinishing® provides a greater power density
for planetary gears in trucks and tractors: reducing the
amount of heat treat distortion means smaller and lighter
and yet more powerful gearboxes can be designed. The
method and tool was introduced to the global public for the
first time at EMO 2025.
SkiveFinishing® is based on the same kinematics as gear skiving
further information: www.liebherr.com
24 no. 4, November 2025

processes
25 years of proven safety
EDM machines always carry a potential fire risk.
During the EDM process a spark is generated, which
is normally shielded from oxygen by a dielectric fluid
– usually oil-based. However, if oxygen reaches the
spark a fire may ignite.
In practice, the dielectric is supplied via adjustable hoses. If
operators fail to position these carefully, the risk of fire increases
significantly. Other factors – such as unsuitable electrodes
or incorrect process settings – can also trigger a fire.
For this reason today EDM machines are fully enclosed
and equipped with fire suppression systems as standard.
Nevertheless, even short fires can cause major damage: cables,
motors, measuring systems, or protective bellows may be
destroyed, processes interrupted and machines taken out of
service. Even if the fire suppression system activates in time,
the fire extinguisher must be replaced after use – inevitably
resulting in downtime.
Temperature sensor
To prevent exactly this LACH DIAMANT developed a
pioneering fire warning system in 1999 for all EDM machines
used in PCD tool machining. At its core is an ultra-fast
temperature sensor, positioned directly above the spark.
When detecting a fire, it immediately shuts down the generator
and the dielectric supply, stops the EDM process,
and alerts the operator. In essence, the fire is deprived of
oxygen – in nine out of ten cases it extinguishes instantly.
In most situations it is sufficient for the operator to simply
correct the position of a hose. The process can then continue
without restarting the machine – resulting in zero downtime.
If the fire persists an independent CO₂ fire suppression
system takes over.
Infrared sensor system
One year later, in 2000, LACH DIAMANT went even further:
a multi-stage sensor system was introduced. In addition
to the temperature sensor, an infrared camera has since
moni tored the entire machine chamber. The system first
shuts down all units – and only in a second stage activates the
CO₂ fire suppression system.
Today – 25 years later – every EDM machine for PCD tool
machining is delivered with this triple safety concept as
standard. The result: since its introduction, not a single
customer with the installed and activated system has suffered
serious fire damage.
On the contrary – the fire warning system has prevented
thousands of minor fires from escalating, without ever
requiring the CO₂ fire suppression system to intervene. This
not only avoids costs and downtime but has also saved countless
tons of CO₂ emissions.
Fire warning system
further information: www.lach-diamond.com
no. 4, November 2025
25

processes
Stator machining solution ready for series production
New standards set
A process for the complete machining of stator
housings for electric motors developed by the
Chemnitz machinery manufacturer NILES-SIMMONS
and tool manufacturer MAPAL has made it to series
production.
Suppliers and OEMs are now using it to produce high-efficiency
components designed for drives for battery-powered
electric vehicles and hybrid models from major automotive
manufacturers.
Both manufacturers recently proved in a development
project that highly cost-efficient and precise production of
stator housings is possible on a pick-up lathe. The thin-walled
aluminum components are required for the drive in electric
vehicles. They are ribbed on the outside for the cooling circuit
and are installed in the larger motor housing.
While a converted modular lathe had been used by NILES-
SIMMONS during the development stage, a machine
specifically designed for stator production now hit the
market. The basis for development was the vertical machining
center from the RASOMA brand, which, like
NILES- SIMMONS, is an NSH Group (NILES-SIMMONS-
HEGENSCHEIDT GmbH) brand. Both brands are organized
together in the NSH Group subsidiary NSH TECHNOLOGY
and have together pressed ahead with the development. The
name RASOMA DZS 400-2 indicates that it operates with
two workpiece spindles.
For use in series production the machine was equipped on
the sides with a pick-up area for raw parts and a drop-down
area for finished parts. The components are supplied and
removed via conveyor belts. With manual assembly a buffer
of ten to twenty components can be used via automation.
This makes operating multiple systems possible while the
employee can pursue other processes alongside production.
“We have realized highly simple automation as standard. No
robots or blocks on the machine are required. Operators can
place the parts directly on the pallet belt”, explains Thomas
Lötzsch, sales manager at NSH TECHNOLOGY. Fully automated
workpiece loading and unloading for several machines
with a central conveying system is optionally available. The
machine is easy to integrate into an existing production
environment. The relatively compact installation dimensions
of 7.50 x 2.60 m contribute to this. The basis for the design
of the RASOMA DZS 400-2 was created in collaboration
with LTH Castings, a partner with lengthy experience in casting
and a specialist in machining complex, high-quality and
thin-walled components from pressure die cast aluminum.
Therefore, the design took directly practical experience and
user requirements into consideration.
Complete machining in two clamping systems
Between pick-up and drop-down, the complete finishing of
the components takes place on the vertical machine in two
clamping systems. A clamping device first of all picks up
the workpiece from above and moves it to various machining
stations in the machine one after another. At a re-clamping
station in the working area, the part is turned 180 degrees
and picked up by the second workpiece spindle for finishing.
During the second clamping, machining of the next component
begins at the same time at the first pick-up.
The machining steps follow one another, like on a miniature
transfer line. The process begins with the pre-roughing
of the component’s various inner diameters. The tool stands
still and the workpiece rotates. “Unlike conventional turning
with a blade, machining with a four-blade ISO boring tool on
a HSK-A 100 spindle takes just a quarter of the productive
time”, says MAPAL regional sales manager André Ranke. The
next machining step, in which the rotating stator housing is
machined inside and outside simultaneously with four blades
each, is also extremely efficient. The inner tool also rotates.
The difference in the tool speed and the workpiece speed produces
the cutting speed at the inner blades. The bell-shaped
outer tool stands still. The component is placed in the gap
between the inner and outer tool for machining. This
patented process reduces forces that occur on the clamping
system, making it possible to avoid using a complex workpiece
clamping device with vibration damping for precise
They brought the new technology to
series production maturity (from left):
Daniel Pilz (project leader NSH TECHNOLOGY)
with the MAPAL sample component,
André Ranke (MAPAL regional sales manager)
with a fine boring tool and
Thomas Lötzsch (sales manager at NSH TECHNOLOGY)
with a customer component
26 no. 4, November 2025

processes
For the second machining step the thin-walled component is placed in the gap between the inner and outer tool
machining of the thin-walled components. “When designing
the tool, particular attention was paid to the large chip
volume and the significant forces generated, as it is unusual
for the inner and outer diameters to be machined simultaneously”,
explains Michael Kucher, component manager
e-mobility at MAPAL.
During finishing only the fine boring tool is driven, while
the component stands still. This prevents workpiece shapes
that are not rotationally symmetrical from causing imbalances
in the material and having a negative impact. The workpiece
is then reclamped in the machine and the outer area
that was previously clamped in the flange area is machined.
The re-clamping station can also be used for another purpose:
the workpiece is placed here before fine boring to relax
the material. The machine has two tool revolvers for driven
tools that carry out further machining based on component
requirements.
Faster and more stable than expected
“The bottom line is that the RASOMA DZS 400-2 brings
together the best of both worlds: the turning speed for pre-
machining inner and outer contour with the accuracy of
fine boring for finishing the inner contour”, says Daniel Pilz,
project leader at NSH TECHNOLOGY. The machine tool
manufacturer and MAPAL contributed their respective core
competences to this complete solution. With the serialization
of the machine, tool technology and process, the positive
results of the prototype were improved even further. The
process reliability achieved even exceeded expectations,
allowing the targeted cutting speed of 700 m/min to be increased
even further. “For this aluminum machining the experience
NILES-SIMMONS brings from the diversity of technology
has a positive impact on the overall reliability of the
tool technology and machine”, explains Michael Kucher,
component manager e-mobility at MAPAL.
The RASOMA DZS 400-2 achieves a much shorter chip-tochip
time than a milling center. This is because all tools are
already in the working area and are only brought into working
position by swiveling the revolver disc. This does away
with all tool changes, reducing non-productive time substantially.
Using this technology a cycle time reduction of 50 %
versus standard turning was already anticipated in studies.
The workpiece is taken to the different machining stations
one after the other in the pick-up turning machine
At the re-clamping station the workpiece is turned
180 degrees and readied for spindle clamping
no. 4, November 2025
27

processes
At RASOMA, the next DZS 400-2 is currently being built;
the pick-up area is on the left, the drop-down on the right,
various machining stations are set up between them
Once the component has been turned, while OP 20 is being
performed at the second spindle, OP 10 for the next
stator housing can begin at the first spindle
During process optimization, cutting speeds of 1,000 m/min
were achieved using optimal cutting material. The additional
optimization of non-productive time resulted in even more
time saving of 20 %.
The process is so reliable that random sampling is sufficient
for quality assurance. While all manufactured components
were measured at first, the current recommendation
is just one part per shift. Daniel Pilz uses figures to demonstrate
that this is more than satisfactory: “The RASOMA DZS
400-2 with the special tools from MAPAL achieves a process
capability index of over 1.67 for critical characteristics, such
as cylinder shape, diameter and concentricity and thus meets
industrial specifications.” Customers for whom the machine
is already in use achieve an annual output of up to 180,000
components produced in three-shift operation.
Successful at high volumes
LTH Castings in Slovenia is among the first users of the serial
process for stator production on the RASOMA DZS 400-2.
The casting firm with a long tradition has over 100 casting cells
and processes the raw parts on over 250 CNC machining
centers. There are around 3,800 employees working at a total
of six sites. Dr. Primož Ogrinec, CTO of LTH Castings: “With
our all-in-one solutions from the design to series production,
we are a key strategic partner for the automotive industry.
Our range includes component for drives, motors for battery-powered
electric and hybrid vehicles, steering and braking
systems.” The RASOMA DZS 400-2 machines are loaded
and unloaded by robots in the ultra-modern production.
Like most automotive suppliers LTH Castings manufactures
components for various vehicle models. The flexibility
of the RASOMA DZS 400-2, in which only clamping devices
and tools need to be re-tooled, is useful for the production of
stator housings. “With a single system and using the new process,
an optimum solution, manufacturer-specific in quantity
and quality, was developed and brought to series production
maturity”, says André Ranke. Stator housing production is
therefore possible up to a diameter of 500 mm and a component
length of 500 mm
“Every kind of housing we’ve seen can be manufactured on
the RASOMA DZS 400-2 – and we’ve seen plenty of them”,
says Thomas Lötzsch. The project team also got a surprise
when a major car manufacturer’s housing design required
an indentation on the inside of the component. The sample
component from MAPAL, specially designed and produced
for the process design, did not present this challenge. Yet
MAPAL very quickly had a joint solution ready with the NSH
Group specialists: instead of the tried-and-tested fine boring
tool, an ultra-precise actuating tool with four slides from the
MAPAL product portfolio was used to create the desired inner
contour. On the machine side, a connection designed in
coordination with MAPAL was ready in a few days. It already
achieved series production maturity during the ongoing
order. As their development structure is now tightly networked,
the two companies are able to react quickly to newly
developed contours.
New benchmark for
low costs per part
The RASOMA DZS 400-2 with the tool technology from
MAPAL has become established in series production and
solves quality issues that occur on conventional turning
and milling machines and horizontal transfer lines. Thomas
Lötzsch tells of cases in which the required shape and position
tolerances were not achieved with reliable processes and
scrap was produced instead – up to 50 %. Where the quality
was right, cycle times left much to be desired and resulted in
higher workpiece costs. An established process for manufacturing
components was lacking.
When the RASOMA DZS 400-2 was being developed, the
focus was on keeping unit costs as low as possible from the
outset, as competition on price is tough among automotive
suppliers. This goal was achieved with a combination of high
machine availability, short cycle times, machined component
quality and production with reliable processes. Current
calculations indicate that machining, including tool costs,
can achieve economical costs per part as a result.
further information: www.mapal.com
28 no. 4, November 2025

processes
Enhanced stability and cleanliness
VOLLMER has further developed its VLaser 370
laser machine and perfected series production, particularly
in terms of enhanced stability and cleanliness.
Thanks to its sophisticated kinematics, improved extraction
technology and internal compensation measure
ment, the VLaser 370 can be continuously operated
for months – without corrections or cleaning.
Anyone wishing to test the benefits of the laser machine can
do so either by machining sample tools at VOLLMER or by
leasing a machine on-site. This also enables more extensive
tests over longer periods of time.
“Our extensive series of tests has indicated that our
VLaser 370 runs reliably for months without a warm-up program
and without any diameter or length correction” ,says
Christopher Lang, product manager at VOLLMER. “We have
achieved this by improving and stabilizing removal technology
and a compensation measurement that calibrates within
seconds before each tool, among other measures.”
Producing complex tools
with the power of the laser
The Biberach-based sharpening specialist has once again
decisively improved the VOLLMER VLaser 370 machine
as standard, adding functions such as defined cutting edge
rounding and increasing efficiency during continuous operation.
Innovative kinematics, future-proof components and
outstanding thermal stability combined with impressive
The VOLLMER VLaser 370 machine achieves its high stability
and precision thanks to tool machining based on the C axis in
the center of the focal point of the laser light
user-friendliness guarantee smooth movements, energyefficient
operation and strong results. In principle, tool manu -
facturers can use the laser machine and the relevant automatic
settings to machine any tool made of ultra-hard cutting
materials such as PCD (polycrystalline diamond), CVD diamond
or PcBN (polycrystalline cubic boron nitride) without
manual intervention, and around the clock. The VLaser 370
is ready for use without warm-up times to produce different
cutting tools precisely and with repeat accuracy.
Even for complex tools such as thread profiles or closed
contours with recesses, such as in circular milling tools, all
one needs to do is select a standard technology that delivers
the desired result, without prior machining and with just one
partial contour. And this is the case without strong equalizing
movements with perfectly mapped axial and radial clearance
angles – even the smallest inner radii of 50 mm, and even
as small as 20 mm, are not a problem. The machine also performs
tasks that only a laser can do, such as the production of
chip guide notches or chip deflectors. Chip guide notches are
incorporated directly behind the cutting edge, and are used
to remove the chips produced.
VLaser 370 scores points with
extra stability and cleanliness
The high stability and precision are achieved by tool machining
based on the focal point in the center of the C-axis.
Here the tool is only moved by minimal equalizing movements
during the sharpening process. This is possible because
the laser source and the beam guide are firmly attached
to the central block made of polymer concrete. The fact that
the VLaser 370 remains ready for use for months even in
continuous operation without any corrections or cleaning is
also due to the machine’s optimized extraction concept. This
allows better extraction of vaporized microparticles, which
in turn prevents contamination of the protective glass in
front of the palm-sized lens.
The VLaser 370 is not only suitable for tool manufacturers
in the metal, wood and plastics industries, but also goes
beyond the tooling sector. Alternative applications such as
cylindrical machining in the micro range, surface perforations
or other forms of material removal in the machining
chamber up to a diameter of 150 mm are possible. Tool manufacturers
and interested parties from all sectors can test the
VLaser 370 with immediate effect at VOLLMER in Biberach
for machining of sample tools. The machine manufacturer
also offers cost-effective leasing options for the VLaser 370,
so that customers can test the laser machine over longer
periods of time and integrate it into their own production
environments.
further information: www.vollmer-group.com
no. 4, November 2025
29

processes
Specialists in
ultrasonic deburring
Every machining process produces unwanted burrs
and protruding fibers in and on components. The
technology company ultraTEC innovation GmbH has
developed a new process to remove these automatically
and contact-free: its systems deburr metal and plastic
components with the power of ultrasound.
For this purpose components are guided along in a process
water basin along the tip of an ultrasonic sonotrode, whose
generated vibrations cause the burrs and fibers to break off
in an energy-efficient manner. Since July 2022 the start-up,
founded 2019 in the southwestern German town of Laupheim,
has been a company of the international VOLLMER GROUP
from Biberach an der Riß.
Successful “Jugend forscht” project
with Rayleigh waves
At “Jugend forscht 2019”, German national youth competition
for STEM subjects, 17 year old Jakob Rehberger and 16
year old Jonas Münz were awarded the German President’s
Prize for Outstanding Work – acknowledging them as the best
young scientists. Under the project name “ultraTEC – and the
burr is gone!” they presented an ultrasonic deburring process
which could be used to deburr titanium bone implant screws
used by doctors for bone injuries. Prior to that it was only possible
to use ultrasonic deburring on components made from
plastic or aluminum. The young researchers were able to generate
Rayleigh waves via indirect ultrasonic irradiation. Other
than that, Rayleigh waves are generated during earthquakes
and are feared because of their destructive potential. In the
ultrasonic deburring process the force of the Rayleigh waves
is used on components in a targeted manner, to deburr even
internal edges and the smallest cross holes in a contact-free
and process-safe manner.
Project transformed into a family-run business
Even before Jonas’ success in the “Jugend forscht” competition,
his parents – Iris and Dieter Münz – had already decided
to turn the project into a business. The company’s name,
ultraTEC Anlagentechnik Münz GmbH, drew inspiration
from the name of the project. Not even a year later, the
Laupheim-based start-up developed its first market-ready
ultrasonic deburring system and brought it onto the market.
Two years later, in summer 2022, the start-up found a strong
partner for strengthening and expanding its sales and brand
identity globally in the Biberach-based VOLLMER Group.
The company now operates under the name “ultraTEC
innovation”. Nevertheless, contact-free ultrasonic deburring
with the patented sonotrode remains the foundation of
ultraTEC. Machining metal or plastic, whether by means
of drilling or milling, produces unwanted burrs and fibers
on edges, cross holes and surfaces. In addition to deburring
common metals, ultraTEC systems can also be used with
components made from various titanium and nickel alloys,
brass and fiber-reinforced plastics.
Ultrasonic deburring with
high-frequency sonotrodes
In the process developed by ultraTEC components are guided
along in a process water basin past the high-frequency ultrasonic
sonotrode. Stimulated by a generator, the sonotrode oscillates
back and forth 20,000 times per second over 0.1 mm.
These generated vibrations move burrs and fibers back and
forth until they are broken off with sharp edges in a processsafe
manner. Users can dispose of the process water without
any problems and without further treatment.
Compared to conventional methods, ultrasonic deburring
is the only method that can be implemented fully automated,
virtually independent of the material, contact-free, energyefficient
and with a process that can be validated. By contrast,
thermal processes, for example, burn away burrs, which can
discolor and deform the components. Likewise, ECM (electrochemical
machining) processes are often not possible with
small components because they cannot achieve a definable
material removal rate. High-pressure waterjet deburring
requires around 20 times as much energy as ultraTEC’s
ultrasonic deburring systems when machining comparable
parts. Ultrasonic deburring is even a viable alternative for
components that are difficult to deburr and currently require
manual deburring.
Ultrasonic deburring system features a
digital control system
In ultrasonic deburring systems individual components are
guided along the firmly anchored tip of the sonotrode at a defined
angle with the aid of an industrial robot that can operate
24/7. For microparts that cannot be gripped with a robotic
arm, ultraTEC has developed a process in which the sono -
trode is positioned flexibly on the robot arm and guided along
the component. Tool manufacturers and machine manu factur
ers can also use ultraTEC systems to gently deburr sensitive
surfaces. The range of components that can be machined
extends from microparts for the optics or watchmaking indus
try, to precision tools for machining, to 20 kg elements required
for mechanical engineering or vehicle construction.
further information: www.ultratec-anlagen.de
30 no. 4, November 2025

Compact angular plunge-cut grinding machine
improves production processes
processes
Over the past 50 years Wandel CNC-Technik GmbH
has developed into an established supplier with its
own product portfolio. The Swabian family business,
which is now managed by the second generation, has
continuously expanded its production spectrum: from
milling to turning and grinding. By investing in an
EMAG WPG 7 angular plunge-cut grinding machine,
the company has expanded its grinding capacities in
a targeted manner.
Diverse production spectrum requires
flexible technologies
The company has 23 employees and produces between 15,000
and 20,000 components per month. The product range includes
forged blanks, drive shafts and intermediate flanges
for the commercial vehicle industry as well as classic machine
components such as worm shafts. In the milling area the focus
is on gearbox housings made of aluminum, steel and cast iron.
In grinding, the company concentrates on symmetrical or
round components with diameters ranging from 10 to 150 mm
and lengths of up to 1,000 mm.
Wandel CNC-Technik’s own product portfolio includes
ball screw nuts, which are manufactured in sizes between 16
and 50 mm. These are mainly used in handling technology,
for adjusting platforms and in mechanical engineering.
Targeted investment in grinding technology
The WPG 7 is the fourth grinding machine to be added to
the company’s machine park. It was purchased specifically
for the machining of flange nuts, for which angular plungecut
grinding is a technological requirement. The machine
is designed for batches of between 20 and 200 pieces and is
retooled up to twice a day at high capacity. The decision
for a dedicated angular plunge-cut grinding machine was
Finished sleeve with precision machined end faces,
produced on the EMAG WPG 7 grinding machine
The compact work area of the WPG 7 enables
precision angular plunge-cut grinding
based on several factors: the company already had a straight
plunge-cut grinding machine for long and larger components.
The compact design of the WPG 7 enables short travel
distances and fast movements – a significant advantage over
larger universal machines. The limited space at the site also
spoke in favor of the compact solution.
Technical advantages optimize
the production process
One particular advantage of the WPG 7 is its thermal stability.
The compact design significantly reduces heat transfer, which
means that the machine works with precision immediately
after being switched on. The angular grooving technology
shows its strengths particularly in the machining of flanges
that need to be ground for squareness or axial run-outs.
Com pared to previous machining methods, shorter running
times and higher qualities are achieved. The modern control
system of the WPG 7 enables user-friendly programming
directly at the machine, whereby the programs for around
50 different components can be saved and called up again as
required.
Increased efficiency through adapted technology
The investment in the WPG 7 has paid off for Wandel
CNC-Technik in several respects: the compact design ensures
optimum use of space and the thermal stability guarantees
consistently high quality, while the angular plungecut
technology enables better machining results for flange
parts. The short travel distances and ease to operate con -
tribute to increased efficiency, while the quick installation
and good support from EMAG enabled a smooth transition to
production.
further information: www.emag.com
no. 4, November 2025
31

machining center
Advanced honing solution for
demanding industrial applications
Sunnen Products Company, a global leader in highprecision
bore finishing and measurement, highlights
the HES External Honing Machine, a high-performance
solution engineered to deliver precision, produc -
t ivity, and versatility in external honing applications.
Specifically designed to meet the rigorous standards of industries
working with oversized components, the HES sets a new
benchmark for performance and ease of use across a wide
range of large parts and materials.
The HES Honing Machine is capable of machining nearly
all advanced materials, including electroplated hard chrome
and plasma-sprayed surfaces, and laser cladded layers offering
users remarkable versatility for a wide array of large-scale
materials and manufacturing environments. Its dynamic
rack-and-pinion stroke system and optimized spindle drive
ensure consistent and powerful performance across the
entire diameter range.
The rack and pinion design of the HES machine is modular
and can be extended onsite at a later stage if needed. With
the ability to remove up to 1,400 cm³/h of stock, the HES
dramatically reduces cycle time on large parts while delivering
an impeccable surface finish suitable for the most
demanding specifications in heavy-duty applications. For
example, for customers applying a laser cladding layer, mechanical
dechroming can be a significant benefit, but with the
HES External Honing Machine there is no need to chemically
de-chrome the part as this will be done as part of the
honing process. The stock removal rate for chrome reaches
an impressive 500 cm³/h (or 30.5 in³/h), which is much faster
than any other chrome removal processes, and provides a
more positive environmental impact on this kind of hardchrome
removal.
The typical crosshatch pattern associated with honing
is also applicable to the external honing process. Surface
structures like plateau finishes and bearing surfaces offer a
significant advantage in today’s industrial applications. For
example, a honed piston rod has been shown to significantly
extend the lifetime of seals.
Ease of use is at the forefront of the HES Honing Machine’s
design. The intuitive touch control interface and self-guided
setup process simplify operation, eliminating the need for
programming skills and minimizing downtime and training
requirements. Fast setup, with new configurations achievable
in under two minutes, is complemented by step-by-step guidance
and a system that recommends spindle speed and necessary
cycle parameters, optimizing process results every time.
With an unmatched cost advantage and return on investment
compared to traditional grinding and belt grinding systems,
the HES model reduces operational costs and boosts profitability
for manufacturers working with large, high-value
parts.
Even on long, smaller rods below 80 mm in diameter and
lengths above 6 m, external honing proves competitive – even
compared with turning in soft steel. The flexibility of the
hone head, which is completely cardanic with 25 mm float
capacity on each side, combined with the automatic steady
rest support, ensures that setup and honing of these parts is
easy and does not require an experienced operator, unlike
turning operations. With this floating capacity of the HES
external honing machines there is no need to straighten the
parts before honing unlike with turning.
Operators benefit from 100 % process control with tool
overload protection, automatic geometry correction, and con
tinuous tool expansion control, ensuring optimal stock removal,
extended tool life and consistent performance. Optional
automatic workpiece supports, a quick stone holder system,
and a wide diameter range of 50–450 mm with a long stroke
length up to 14,000 mm accommodate a broad variety of
large part sizes, making the machine ideally suited for long
shafts, hydraulic cylinders, turbine components, landing gear
components and other sizable industrial pieces. Automatic
correction of roundness and parallelism ensures dimensional
accuracy throughout lengthy parts, while sizelock and stone
wear compensation maintain precision and reduce the need
for manual adjustments. Dwell, oscillation and spark out
functions further enhance surface finish and process control
on large-scale workpieces.
Maintenance is straightforward and downtime is minimized
with the HES Honing Machine. The machine’s userfriendly
Windows® embedded control system with a 15-inch
screen delivers a modern, responsive interface, a high maximum
workpiece weight capacity up to 12,000 kg and an advanced
coolant system with centrifugal filter, magnetic separator
and oil chiller, all contribute to process stability and
extended tool and workpiece life. Comprehensive safety features,
including CE certification and light curtains, provide
operator safety and regulatory compliance, while optional
software for taper bore applications expands the machine’s
capability for specialized honing tasks on large parts.
With the HES External Honing Machine Sunnen reinforces
its commitment to innovation, productivity, and total honing
solutions. The system’s unmatched capability for handling
large parts and demanding materials makes it a valuable
investment for operations requiring precision and reliability
across a broad spectrum of industrial applications.
further information: www.sunnen.com
32 no. 4, November 2025

Worldpremiere:
machining center
High-end wire EDM for the highest levels of precision
UNITED MACHINING announced the world premiere of the AGIE CHARMILLES CUT S
series at EMO Hannover 2025, presenting three new S-series models for superior precision –
CUT S 400, CUT S 600 and CUT S 800. New S-series redefines high-end wire EDM
with precision, productivity and automation compatibility.
The AGIE CHARMILLES CUT S series is tailored for industries
demanding the highest levels of precision and reliability,
such as tool and die making, automotive, aerospace, medical
device manufacturing, ICT and precision engineering. The
machine is especially suited for stamping tools, molds and
dies, parts production, medical implants and devices
Key innovations of the CUT S series
The new CUT S series embodies the next generation of EDM
machining, integrating advanced mechanical architecture
with proprietary technologies to deliver superior precision,
operational reliability, and user accessibility:
→ The symmetrical machine architecture enhances operator
accessibility and reduces idle time, while enabling
seamless integration of modular automation systems
from any side of the machine. Designed and engineered
for factory automation, lights out manufacturing and
optimization on the shopfloor space – the only fully symmetrically
configurable Wire EDM machine in the world
→ Limitless taper machining enabled by the TETRAX
design ensures equal travel capabilities across the U/Vand
X/Y-axes, while maintaining full Z-axis freedom,
allowing precise execution of complex taper geometries
without mechanical constraints.
→ Reliable precision in any environment: the thermal
compensation system actively adjusts for temperatureinduced
changes in material dimensions, ensuring the
machine maintains precise geometry and alignment.
→ Cut S series is designed with full focus on human safety
and productivity. The ergonomics and accessibility of
the machines bring ease of operation and maintenance
of the machines to the next level. Enclosed machine
design protects both the operator and the surrounding
environment from electromagnetic emissions.
→ The patented Precision Collision Protection system
safeguards critical machine components against
accidental impacts, ensuring maximum operational
uptime and significantly reducing maintenance and
repair costs.
→ Spark Track technologies, featuring ISPS and iWire,
ensure stable, fully autonomous cutting operations while
intelligently optimizing wire consumption for maximum
efficiency and cost-effectiveness. Reliable precision,
even when mistakes happen.
→ Achieving surface finishes as fine as Ra 0.08 μm,
the system sets a benchmark for superior precision
applications requiring exceptional surface integrity
and dimensional accuracy.
A completely new generation
CUT S 400 is the most compact model of the new series,
offering the same high precision and productivity as its
larger siblings. CUT S 600 expands capacity for mid-sized
workpieces.
further information: www.ums.swiss
no. 4, November 2025
33

machining center
State-of-the-art grinding technology in a small space
The S23 universal cylindrical grinding
machine offers high precision, great
flexibility and modern grinding technology
in a compact design at an attractive
price-performance ratio. The S23 was
un veiled to the global public at EMO
trade fair 2025.
“Thanks to its high-quality features, precision
and flexibility, the S23 complements our
portfolio in the entry-level and premium segments”,
explains Sandro Bottazzo, CEO of
Fritz Studer AG. With a compact footprint,
Studer S23
the CNC universal cylindrical grinding machine offers state-of-the-art,
reliable grinding technology. These include the modern C.O.R.E. hardware
and software architecture, an automatic B-axis with 1° Hirth coupling for up
to three grinding tools, frequency-controlled motor spindles or belt drives,
and the machine base made of Granitan® with its outstanding thermal and
vibration characteristics.
Customers also benefit from the innovative design that STUDER has
developed for the S23. The arrangement of the wheelhead allows great
versatility for the grinding tools in a single clamping, increasing efficiency,
especially with geometrically complex workpieces. State-of-the-art grinding
technology such as contact detection, semi-automatic balancing of the external
grinding wheel and the optional in-process measuring system ensure
high-quality results.
Wheelhead
The advantages of the S23
■ compact design
■ distance between centers 650 mm / 1000 mm
(29.6” / 39.4”) and center height 175 mm (6.9”)
■ automatically swiveling wheelhead (B-axis)
for two external grinding wheels and
one internal grinding wheel or a
production wheelhead
■ intuitive operation with C.O.R.E. and
StuderWIN
■ standardized automation with
STUDER easyLoad and insertLoad as well as
customized solutions
Optimal solution for a wide range of customers
This makes the S23 the ideal solution for a wide range of customers. With
high accuracy and process reliability it grinds small to medium-sized workpieces,
even with complex geometries, in single and series production. “The
S23 is ideal for production in the tool and die, automotive and supplier,
aerospace and in the medical technology industries”, explains STUDER
sales manager Rolf Grossenbacher. In addition, customers have numerous
configuration options for adapting the machine to their individual production
requirements. These include a C-axis for thread and out-of-round
grinding and an optional swiveling table. Customer-specific adaptations are
also possible.
Thanks to state-of-the-art digital technology and sensor technology, operation
is simple and intuitive. After just a short introduction employees can
achieve reliable, high-quality results using the C.O.R.E. touch panel and
StuderWIN software. Set-up and changeover times are also minimal, thanks
to the practical QuickSet function. Customers who want to automate their
production can do so efficiently and economically thanks to the standardized
loader interfaces for easyLoad and insertLoad. And, of course, they benefit
from STUDER’s worldwide competent customer care and the experience
of a traditional Swiss company with over 111 years of history. “This makes
the S23 a high-precision universal cylindrical grinding machine with an
excellent price-performance ratio”, summarizes CEO Bottazzo.
further information: www.studer.com
34 no. 4, November 2025

Multi-tasking machines unveiled
machining center
The new INTEGREX j-200 NEO and the second
spindle INTEGREX j-200S NEO models are built upon
the ethos of the original multi-tasking j-series models
first launched in 2010. Ideally suited for general subcontract
work, as well as automotive, autosport, aerospace
and medical industries, the models offer a productivity
upgrade for turret lathe users looking to increase
profitability by reducing set-up and lead times.
Crucially, the renewed specification for the NEO machines
delivers a significant increase in productivity, machining
accuracy and environmental performance compared to
previous models.
The INTEGREX j-200 NEO is among the range of 20 machines
that Mazak showcased at EMO 2025, where the firm
exhibited under the theme “Experience innovation, empower
your future”, highlighting the benefits of a real partnership
between machine manufacturer and user.
A key highlight with the new INTEGREX j-200 NEO
machines is the new, compact milling spindle which uses a
built-in Mazak spindle motor to provide a considerable increase
in both power (18.5 kW) and torque (59.7 Nm) to cope
with a broad range of materials and applications. The compact
nature of the new milling spindle, compared to the previous
generation, reduces workpiece interference and increases
the working envelope of the machine.
The main turning spindle, fitted with an 8” chuck, features a
powerful 18.5 kW, 326 Nm built-in motor, with an inte grated
cooling circuit in the headstock to delivery high material removal
rates, whilst achieving stable machining accu racy.
With a Ø 65 mm bar capacity and a Ø 480 mm maximum
swing, the j-200 and j-200S NEO are the ideal platforms for
both automated bar work and robot-fed components.
To facilitate the machining of more complex workpieces,
the INTEGREX j-series NEO machines now offer 0.0001 ° indexing
resolution on the B-axis as standard. A larger 36-tool
magazine – with an option of increasing to 72 – significantly
reduces set up time between component runs, while offering
three times the tool capacity of a turreted lathe with significantly
lower tooling costs compared to driven-tool holders.
The INTEGREX j-200S NEO is also available with a 15 kW
second spindle offering up to 167 Nm of torque, which can help
reduce set-up times for workpieces that require phase alignment.
Both machines are available in 1000 U bed lengths
while the tailstock variant is available in 500 U bed length.
Continuous machining accuracy is enhanced through the
addition of the Ai Thermal Shield function, which uses advanced
algorithms to automatically determine compensation
The INTEGREX j-200 NEO
was one of the highlights on the Mazak stand at EMO 2025
according to fluctuating temperatures, thus improving process
stability for automated production.
Improved environmental performance is a hallmark of the
NEO series of Mazak machines, and the INTEGREX j-200
NEO and j-200S NEO are no different. Both models have
achieved a 10 % energy saving through the use of inverterdriven
hydraulic and chiller units, which only run when required.
A reduction in compressed air requirements has also
helped lower energy consumption.
The new machines are controlled by Mazak’s SmoothG
control system. Housed within an ergonomic control panel
with 19” touchscreen display, it combines MAZATROL conversational
programming with G-code programming to offer
operators the best of both worlds. Users are also able to
program the machines via a 3D Model using the 3D Assist
Function, a feature unique to Mazak.
Both machines are compatible with MAZATROL DX, a
new productivity software that provides users with the capability
to remotely optimize their production process, and
includes features such as the ability to generate rapid automated
quotations, automated part programming, virtual
machine simulation and machine process analysis and optimization.
Additional productivity can be unlocked by integrating
the machines with a Mazak TA (Turn Assist) robotized
machine tending solution. This is available in three configurations
(TA-12 / TA 25 / TA-35) depending on the weight
of the workpiece.
further information: www.mazak.com
no. 4, November 2025
35

machining center
“Experience sparks intelligence”
Gebr. Heller Maschinenfabrik GmbH can look back
on more than 130 years of success. What once began as
a small workshop has developed over generations into
a leading international supplier of CNC machine tools.
But the year 2025 marks a turning point that goes far
beyond technological advances. At EMO Hannover,
HELLER presented itself with a new brand identity
based on the claim “Experience sparks Intelligence.”
This message sums up how the company combines its historical
experience with the latest intelligence to transform
classic mechanical engineering into intelligent productivity
systems. Experience thus becomes a catalyst for the future – a
future in which automation, digital services and artificial intelligence
are not just buzzwords, but create concrete competitive
advantages.
Dr. Thorsten Schmidt, CEO of HELLER, succinctly summarizes
the new direction: “Mechanical engineering is a thing of
the past. Today it’s about how we combine experience, technology,
automation and digital intelligence in a way that
creates real added value for our customers. Together with our
partners we want to design manufacturing that is not only
productive, but also intelligent and future-proof.”
Strategic importance of EMO 2025
For HELLER participation in EMO 2025 meant more than
just a presentation platform. It was the starting point for a
new brand strategy, a milestone on the path from machine
manufacturer to holistic solution provider. EMO is the place
where this transformation became visible – visible in the machines,
in the automation solutions, in the digital services,
but above all in the attitude with which HELLER presented
itself. The company demonstrated that it is ready to take
responsibility and actively lead the industry into the future.
Thorsten Schmidt summed it up: “With ‘Experience sparks
Intelligence,’ we showed that HELLER is much more than
a machine manufacturer. We see ourselves as a partner for
productivity, a driver of innovation, and a companion for our
customers on their journey into an intelligent future. This
attitude shaped our presence at EMO – and beyond.”
Machines and automation – the symbiosis
of precision and efficiency
A key highlight of the trade fair presentation was the HF 3500
in combination with the new RP4 robot cell. This system
exemplifies HELLER’s philosophy of viewing automation not
as a complicated add-on function, but as an integral part of
modern manufacturing. Thanks to its multibatch capability
and intuitive teach concept, a wide variety of workpieces can
be set up flexibly without the need for special robot expertise.
The integrated digital twin supports the operator during
The HELLER 5-axis machining centre F 5000, equipped
with tilt-head kinematics and a rack-type tool magazine,
was on display at EMO 2025; it is especially flexible and
extremely well-suited to the machining of
undercuts and recesses
setup and simulates processes before they are actually exe -
cuted. The result: setup times are reduced, sources of error
are minimized and even unmanned shifts or autonomous
weekend operation become possible. Thorsten Schmidt emphasizes:
“Our customers are under enormous pressure. They
have to manufacture increasingly complex components in
smaller batch sizes with shorter delivery times, while at the
same time facing a shortage of skilled workers. The HF 3500
with RP4 is our answer: an automation solution that is simple,
flexible and economical.”
In addition to the HF 3500, HELLER presented another
technological highlight in the form of the F 5000. This 5-axis
machining center with a direct-drive mill-turn rotary table
is designed for the most demanding requirements, such as
those encountered in everyday applications in the aerospace,
mechanical engineering and medical technology industries.
Thanks to its clevis kinematics and powerful HSK-T-100
motor spindle, even the most complex geometries can be
machined in a single setup. This saves time, increases process
reliability and improves precision. The newly developed
tool rack magazine with mobile rack is particularly innovative
and revolutionizes setup. Tools are prepared in sets and
changed while the machine is running. This drastically
reduces non-productive times while also reducing the workload
for operators. The F 5000 demonstrates how HELLER
transforms technological complexity into a clear competitive
advantage.
36 no. 4, November 2025

machining center
Digital solutions – intelligence that connects
But HELLER doesn’t stop at machines and hardware. At
EMO 2025, the company presented a comprehensive portfolio
of digital and AI-supported services that take the operation
of its machines to a new level. With the ASK.me chatbot
HELLER introduced the first intelligent communication
inter face between humans and machines. Whether for
maintenance, error analysis or status queries, ASK.me understands
the language of the operator and provides clear,
context-related answers. The chatbot uses the collective
knowledge of HELLER and its users and becomes smarter
with every interaction.
This is complemented by the HELLER Services Interface
(HSI), which creates transparency throughout the entire
machine life cycle. Production data is not only collected, but
also evaluated using AI and visualized in an understandable
form – as text, diagrams or tables. This reveals optimization
potential, enables preventive maintenance to be planned
and helps avoid unplanned downtime. With the myHELLER
customer portal, users also have access to spare parts, service
information and an overview of their entire machine park at
any time – regardless of location, intuitively and efficiently.
The SETUP, PRODUCTION and QUALITY Assist systems
also demonstrate how consistently HELLER focuses on
the operator. They accompany the operator throughout the
entire process chain – from setup to production to quality
assurance. This not only increases efficiency, but also enhances
safety and ensures quality.
further information: www.heller.biz
Efficient and flexible
High flexibility in compact design: the new KNG 5P
expert profile grinding machine from KAPP NILES is
ideal for the precise machining of external and internal
gear teeth. As a next level development of the success -
ful ZE series, it combines the advantages of the previous
model with enhanced features.
“The KNG 5P expert can be used for a wide variety of applications
and enables efficient work with excellent gear quality”,
emphasizes KAPP NILES product specialist Boris Maschirow.
Ergonomic handling
The KNG 5P expert is characterized by its outstanding setup
efficiency. To change the diamond dressing tool the direct
driven dressing spindle swivels into an ergonomic accessible
position. Dressing tools can thus be conveniently changed
from outside the machine. The optimized tailstock features
a stroke of 850 mm, and a swiveling mounted tailstock with
adjustable pressure up to 2,000 N significantly extends the
range of applications for clamping between centers.
Wide range of applications
From gear wheels to pinion shafts and worms, the KNG 5P
expert can grind a wide variety of workpieces with a face
width of up to 670 mm. The powerful grinding spindle is
direct driven with speeds of up to 9,500 rpm and drive torque
of up to 64 Nm. This allows the use of grinding wheels with
diameters ranging from 60 to 350 mm.
The 400 mm diameter rotary table is a direct drive solution
and features a deep bore for long shafts. Despite its extremely
wide range of applications and sturdy main components,
the machine has a small footprint thanks to its compact
design.
Additional options
Complex modifications can be produced efficiently and
almost twist-free by means of double-flank grinding on the
KNG 5P expert thanks to 5-axis interpolated grinding via an
KAPP NILES presents the new profile grinding machine KNG
5P expert
open swiveling axis. For grinding worms, the dressing arm
swivels completely out of the working area of the grinding
slide, allowing the full stroke of 675 mm to be used.
The machine can be equipped with automatically CNCcontrolled
cooling lubricant nozzles. In addition, the KNG 5P
expert can be optioned with a loading hatch for automated
loading of the machine.
“With the KNG 5P expert we are consistently continuing
our long-standing successful ZE series. In addition to all the
advantages of this proven series, the profile grinding machine
impresses with additional and new features that offer
the user maximum flexibility”, summarizes product specialist
Boris Maschirow.
further information: www.kapp-niles.com
no. 4, November 2025
37

machining center
Productivity taken further
“Automation has a name: FANUC.” That was the
motto of this year’s FANUC booth at EMO 2025 exhibition
in Hanover, Germany. An increasing number
of manufacturers from a wide range of industries are
turning to FANUC technology – a trend clearly visible
at the trade fair.
Visitors gained an insight into FANUC’s technology as a
reliable partner for machine users, manufacturers and integrators.
The focus was on the presentation of a brand-new
CNC series, the 500i-A. A spectacular ‘cube’ made up of
video displays provided a dynamic 3D experience.
This CNC delivers huge advances in user interface, process,
digital and network technologies. For instance, machine
users benefit from 2.7 times higher CPU performance, allowing
faster cycle times, enhanced 5-axis simultaneous capabilities
and better surface quality. Machine builders gain from
support for a wider variety of machine configurations, while
system integrators can take advantage of easier integration
with digital technology to aid Industry 4.0 transformation
projects.
Simulate to accumulate
The 500i-A is part of the broad factory automation offer. By
way of example, machine users will discover they can simulate
and test all of the companies CNC-controlled machining
applications digitally. An interactive display on the booth
was set to involve high-performance milling, highlighting
how manufacturers can generate real-time digital representations
of machining processes using the powerful software
solutions that include advanced G-code simulation and
Smart digital twin technology.
Also shown was the FIELD system Basic Package data platform.
New features include AI Servo Monitor software to
detect anomalies and help maintain machines, while users
can also benefit from a more flexible adoption process using
either the preconfigured FIELD BASE Pro hardware or a
Virtual Machine installed on their own IT infrastructure.
Among the factory automation highlights for machine
builders will be the enhancement of FANUC iPC (industrial
PC) performance following the introduction of 11th Gen
Intel Core processor technology and Windows 11 support.
Importantly, both the iPC and new 500i-A CNC fulfil the
IEC 62443 international cybersecurity standard for industrial
automation and control systems.
A core development area is the generation of energy savings.
The new αi-D servo and spindle drives provide a pertinent
example, where adoption typically delivers a 10-15 % reduction
in power loss against previous generation drive systems,
as well as up to 30 % less space requirements.
Unmasking the future of machine tools
The machine tool highlight was the first European showing
of the company’s new ROBODRILL C series machining
center, which offers higher accuracy thanks to improved
thermal displacement measures and compensation. Machine
users can also take advantage of a new higher acceleration
spindle, improved ease of use and more energy savings via
the company’s new αi-D servo and spindle drives.
Visitors could gain a glimpse of the stunning results
achievable with the company’s advanced CNC technology
and precise machining centers when observing a ROBODRILL
simulating the 5-axis machining of an aluminum Samurai
mask. The company and its partners scanned the original
mask at Samurai museum Berlin, and now the ROBODRILL
can produce the freeform Samurai mask in a 28-hour
cycle.
Another ROBODRILL performed the live power skiving
of gears with a turning function in four axes. The display
demon strates the efficient manufacturing of small gears, such
as those for pumps or electric bicycles, in a compact set up
with multi-axis functionality.
For visitors with an interest in the latest wire EDM technology,
the booth hosted a ROBOCUT α-C400iC automated
with a CRX collaborative robot (cobot) and the reliable
AWF 3 (Automatic Wire Feed) technology.
Reaching new horizons
Among the robot demonstrations was a robot milling cell
featuring the M-810/270-27B, which was making its debut
appearance in Europe. This high-precision, high-rigidity
robot will use its spindle-mounted end effector to perform
the high-speed milling and drilling (with coolant) of a cast
steel part. Support comes from the company’s new R-50iA
robot controller and its high-accuracy motion, presenting a
cost-effective machining solution as one of the supplementary
methods to the traditional machining process.
further information: www.fanuc.eu
38 no. 4, November 2025

New standards in tool processing
machining center
The latest VISION LASER laser processing
machine from Walter Maschinenbau GmbH offers innovative
laser technology for a wide range of applications
for brazed tools in modern tool production. The
design of the machine is based on the HELITRONIC
VISION, which has been tried and tested and been reliable
for decades.
The laser technology used offers industry-proven reliability
for the precise and efficient laser processing of tools with high
quality requirements.
Versatile application options
The VISION LASER offers all options for processing:
→ PCD (polycrystalline diamond)
→ CVD (chemically deposited diamond)
→ MKD (monocrystalline diamond)
→ carbide
Precision and versatility
The VISION LASER industrial laser system enables:
→ areas of application: the areas of application are e.g. end
mills, ball nose end mills, step tools and many more
→ chipping and crack-free cutting edges: perfect for fine and
coarse grits, increasing performance and
maximizing wear resistance
→ machining of complex geometries: complex
3D geometries such as chip breakers and concave internal
contours can be created with maximum accuracy
→ operation without consumables: no need for cooling
lubricants, filters or wires, which reduces resource
consumption and operating costs.
Laser versus wire erosion
Until now wire erosion has been the standard in the production
of brazed PCD tools, with the disadvantage of consuming
materials such as wires and coolant, as well as the risk of
grain breakage and limitations in the production of complex
geometries. This is where VISION LASER comes in, solving
these problems through the use of laser technology.
Compared to wire erosion, the VISION LASER:
→ production in just one clamping operation:
the blank is clamped and the finished tool is removed,
including e.g. chip breaker
→ impressive cutting speed:
up to twice as fast to comparable materials
→ material independence: the hardness and electrical
properties of the material are irrelevant, enabling seamless
processing of even the hardest composite materials
→ highest surface quality: finest roughness values (Ra),
ideal for high-performance tools
VISION LASER calibration unit and tools
Software integration and user-friendly operation
The software used is GTR ProfDia Laser as a classic application,
which is similar to GTR ProfDia Erosion, which has
been widely used in wire EDM for decades and thus offers
GTR-experienced users an easy introduction to the operation
of the new laser machine.
Advantages of C.O.R.E.
C.O.R.E., one of the most modern machine operating
systems currently available on the market, is used as the basic
operating system. All system applications such as calibration,
warm-up etc. are therefore also 100 % pure C.O.R.E.
applications.
→ automatic calibration: precision made easy; the automatic
calibration of the axes, the laser focus position and
the turning center enable minimal operator effort and
highly precise and efficient manufacturing processes
→ sustainability: continuous monitoring of machine
consumption data such as air consumption,
energy consumption, laser & scan head and
temperature monitoring
→ live process cameras: three cameras are optionally
available for calibrating the blanks and monitoring the
processing, which can display the processing process
in an overview or individually in full screen mode
→ Robot Loader 25: the WALTER Robot Loader 25, which is
available in the portfolio of grinding & eroding machines
since years, can hold up to 70 HSK tools and is now
directly integrated into the C.O.R.E. operating system
further information: www.walter-machines.de
no. 4, November 2025
39

machining center
New developments for the future
of manufacturing
With eight world premieres DMG MORI is once
again taking its product portfolio a big step forward.
The latest developments are 100 % oriented towards the
pillars of Machining Transformation (MX).
For example, new models in 5-axis simultaneous machining
– the DMC 55 H Twin and the DMC 65 monoBLOCK
2 nd generation, as well as the DMU 20 linear 3 rd generation –
serve as the perfect entry point into complete machining
through process integration. The ULTRASONIC 60 Precision
goes one step further. It also combines 5-axis milling
with ultrasonic-assisted precision machining and offers a positioning
accuracy of 4 μm as standard. As the new universal
turning machine in the portfolio, the powerful and versatile
NLX 2500|1250 2 nd generation proves its importance in the
context of the Machining Transformation (MX). In addition,
thanks to its 2 turn-mill spindles, the NZ DUE TC* combines
the characteristics of a highly productive production lathe
with turn-mill complete machining.
In addition, the DMV 200 and SPRINT 420 will be presented
as the new machines. Each of these world premieres
can be flexibly automated in order to optimally utilize production
capacity. The new AMR 1000 supports this area
as another driverless transport system for the autonomous
handling of tools, material pallets or chip trolleys.
Repeat accuracy and productivity
Additive manufacturing offers the potential to
optimize process chains, increase their efficiency and
conserve resources. As a full-line supplier in the machining
of metal components, DMG MORI combines
both conventional CNC machines and additive technologies
such as powder deposition welding on the
LASERTEC DED hybrid models and the powder bed
process in the form of the LASERTEC SLM series in its
product range
With the LASERTEC 30 SLM 3 rd generation introduced in
2024, the company is setting new standards in this field. Both
its expertise in additive manufacturing and its many years
of experience in machine tool construction have gone into
the development of the powder bed machine. A frame made
of cast components acts as a highly rigid base, enabling the
company’s latest powder bed machine to redefine robustness
and repeatability. While dynamic forces are generated by
axis movements in conventional machine tools, thermal expansion
due to temperature changes is the biggest challenge
in powder bed technology. The process chamber is floating
within the cast frame and can expand freely in response to
temperature fluctuations. At the same time the high-precision
optical modules – with a spot diameter of 80 µm – are
firmly mounted on the cast frame. Precise calibration of the
coater using a reference surface ensures a constant distance
between the optics and the powder bed, additionally supported
by active temperature compensation of the positioning
in the Z-axis.
To make the manufacturing processes in the powder bed
more efficient, the company has equipped the LASERTEC 30
SLM 3 rd generation with up to four lasers with a power of up to
1000 W, whose scan fields completely overlap. For short nonproductive
times, the construction container – measuring
As stable as a
machine tool, four lasers, a large installation
space and optics with a spot diameter of 80 µm: the
DMG MORI LASERTEC 30 SLM 3rd generation sets
new standards in terms of robustness and repeat accuracy
325 x 325 x 325 mm – can be equipped with up to four lasers
with a power of up to 1000 W, whose scan fields completely
overlap. For short non-productive times the construction
container – measuring 325 x 325 x 400 mm – can be changed
before it has cooled down. Covers for the build container and
the working space are stored in the working space during
operation. They serve to seal the build container during
removal and to maintain the inert gas atmosphere in the
machine. The next build job can thus be started quickly without
having to refill the machine with inert gas.
At EMO, DMG MORI presented the LASERTEC 30 SLM
3 rd generation live in action: a rocket combustion chamber is
being created in the machine’s build space, which impresses
with its improved cooling efficiency and lightweight, monolithic
design.
further information: www.dmgmori.com
40 no. 4, November 2025

Technology portfolio expanded to include
turning and milling
machining center
Kellenberger is consistently pursuing its growth
strategy and expanding its technological foundation.
Under the slogan “One name, one brand, endless
possibilities” the well-established brands Voumard,
Hauser, and Tschudin will now operate under the
brand Kellenberger. In addition a new machine series
will be introduced, expanding the company’s core
grinding technology to include turning and milling.
The first machine developed under this new direction,
the KELLENBERGER TM300, made its debut at EMO.
New CEO Carsten Liske describes the company’s global
strategy: “In the future we aim to offer Kellenberger customers
not only innovative grinding solutions, but also wellthought-out
machine concepts in the fields of turning and
milling – the kind of solutions Kellenberger has been known
for over decades. With the KELLENBERGER TM300 we’ve
developed a multifunctional machine for complex machining
tasks that demand the highest precision and maximum flexibility.
The TM300 complements our successful high-precision
SP series machines.”
The company’s service commitment applies across all
series and technologies. From predictive maintenance and
outstanding after-sales support to comprehensive spare parts
availability via the company’s service platform, the company
offers a wide range of services.
The KELLENBERGER TM300 is a
state-of-the-art 5-axis turning-milling center
Equipped with a Siemens “Sinumerik One” control system,
the machine is ideally suited for demanding applications
in precision engineering, aerospace, medical technology
and general mechanical engineering. The main and counter
spindles offer high performance with 3,500 rpm and 600 Nm
of torque, while the milling spindle delivers 12,000 rpm and
100 Nm of torque. The direct-drive B-axis offers an extended
swivel range of 240 °, and the orthogonal Y-axis with 300 mm
travel provides a large machining area. User-friendliness is
significantly enhanced by the integration of a digital twin.
The proven KELLENBERGER K100 platform concept is
now available with a grinding length of 1,700 mm
The TM300 is optionally available with a lower turret,
enabling complete machining of complex workpieces in a
single setup. For the machining of long shaft components,
a hydraulic steady rest is available.
Kellenberger also presented new solutions
in its core grinding segment at EMO
The highly successful KELLENBERGER K100 is now available
in a version with an extended machine bed for workpieces
up to 1,700 mm in length and a workpiece weight of up to
200 kg, with center height up to 250 mm. This K100 version
can also be configured with up to 10 compact grinding head
variants to optimally tailor the machine to the parts being
processed. The diagonal grinding head arrangement is complemented
by a collision-free universal design with a 500 mm
grinding wheel diameter.
Like all of the company’s grinding machines, the K100 for
workpieces up to 1,700 mm in length is equipped with the
latest BLUE Solution software, which features the newly
developed gSHAPE tool. This part-oriented graphical programming
interface enables visual and intuitive creation
of machining programs.
In the field of coordinate grinding, the company presented
its new WHITE Solution software on the KELLENBERGER
H2000 at EMO. WHITE Solution is an innovative CAD/
CAM solution developed in collaboration with renowned
software specialist OpenMind and based on HyperMill. This
solution enables even more efficient and precise machining
while improving workflow integration.
From the internal grinding segment the company showed
the high-end universal cylindrical grinding machine VM1000,
as well as the VM30, which is specifically designed for smaller
workpieces and equipped with Rex automation.
The 5-axis turning-milling center KELLENBERGER TM300
further information: www.kellenberger.com
no. 4, November 2025
41

machining center
Five-axis machining with the highest precision
in a new dimension
Since years customers have been asking for larger
parts in Kern quality. The new Kern Fortis HD fiveaxis
machining center addresses this request and will
be available for larger parts with the highest precision
as of spring 2026. While the external dimensions only
grow about 50 % compared to the Kern Micro HD, the
generous machining space allows twice the travel.
Eight years ago the Kern team began to realize the dream of
achieving the incredible accuracy of the Micro HD five-axis
machining center in other dimensions, up to twice as
large. Now the dream has become reality and has a name:
Kern Fortis HD. Introduced for the first time at EMO 2025;
delivery will be possible from mid-2026 onwards. Among
others, industries such as mold and die as well as many different
shops can now benefit from Kern’s experience and
achieve unknown results.
Kern managing director Simon Eickholt is excited
about the innovation. Nevertheless he explains matter-offactly:
“The Fortis HD is not only visually very close to our
Micro HD. It was also the template for our developers in
terms of technology and usability, so to speak, and has correspondingly
many similarities.” He then adds more emotionally:
“I still find it unbelievable that we have succeeded
in transferring the unrivalled precision achieved with travels
and many other components to parts that are about twice as
large. Because it’s not like we just take the Kern Micro HD
times two. The Kern Fortis works according to the same principles
but is ultimately a completely new machine.”
The Kern Fortis HD five-axis machining center offers the
well-known, unbelievable Kern precision in a new dimension
Kern accuracy despite a new dimension
To give a face to the part size, travel distances and “unrivalled
precision” in particular: parts for the Fortis HD may
have a diameter of up to 565 mm (22 inches) and be 350 mm
(14 inches) high (Micro HD: D = 350 mm (14 inches),
H = 200 mm (8 inches)). The travels are: X = 780 mm (31 inches),
Y = 420 mm (17 inches) and Z = 450 mm (18 inches) (Micro HD:
350 mm (14 inches), 220 mm (9 inches) , 250 mm (10 inches)).
The machine has a footprint of 4.07 m (13 ft) x 3.05 m (10 ft)
and a height of 3.48 m (11 ft) (Micro HD: 2.65 m (9 ft) x 1.7 m
(6 ft) and H = 2.65 m (9 ft)).
As far as part accuracy is concerned, the Fortis HD proves
the same results as the Micro HD despite being almost twice
the size. The basis for this lies, among other things, in the
positional accuracy of the linear axes. Measurements proved
that the values of the two machines are almost identical.
Circular shape tests confirmed accuracies of less than 1 μm
for the Fortis with the same travel – and even in serial production.
The Kern team is convinced that no other 5-axle
machine of this size can do this to date.
It is also important for applications that the Kern Fortis HD
achieves not only best accuracies but also large chip removal
volumes of up to 1 l/min in steel. Crucially, in addition to
an HSK 40 tool spindle, an HSK 63 version is also available,
which can accommodate tools up to 200 mm (8 inches) in
diameter and 390 mm (15 inches) in length.
Both spindles are designed by the Kern development partner
Fischer as CSC spindles (Compact Shaft Cooling). In
other words the integrated shaft cooling ensures that otherwise
necessary break-in times are minimized – if needed at
all. In addition the spindle remains thermally stable even
at maximum speed and load, which is important for tool
holders and tools. This way users always achieve reliable
milling processes with high removal rates during roughing
and with mirror-smooth surfaces during finishing.
Highlights: micro-gap hydrostatics and
temperature management
A few more technical highlights are essential for the high performance
and precision, which have been transferred to the
Fortis and further developed in the style of the Micro HD. For
example, the developers around project manager Christian
Maier have equipped all linear axes with direct drives and
Kern’s patented microgap hydrostatics. The engineer explains:
“The small gap achieves best stiffness and damping
properties, which ensures the highest surface quality and
accuracy on the workpiece.” At the same time, the integral
design in combination with linear motors makes the drives
particularly robust and reduces energy consumption by
about 80 % compared to conventional hydrostatic systems.
42 no. 4, November 2025

machining center
Temperature management is just as important
for the reliable precision. According to
studies, influence of temperature is responsible
for around 70 % of all accuracy errors
in the high-precision range. “Since we have a
significantly larger machining space, more
moving masses and more power in the
machine with the Fortis HD than with the
Micro HD, it is even more important to get
rid of the temperature directly at the points
where it is generated”, explains Maier, making
it clear that the implementation was a
particular challenge, but ultimately it was a
perfect success.
This means that the temperature management
of the Fortis HD perfectly compensates
the higher heat of the individual compo -
nents. Similar to the Micro HD the linear
motors are cooled and integrated into the
hydrostatic linear axis system. This already
minimizes heat input. In addition, the structures
such as the swivel axis, linear axes and
spindle are also cooled by an extremely precisely
controlled temperature management
system with a volume flow of up to 260 l/min.
Christian Maier explains: “In this way we
manage to keep the temperature in the Fortis
steady at only +/- 0.05 º Kelvin.”
Another particularly charming solution is
the hybrid unit, which is necessary for the
hydrostatic axes and temperature management.
The developers have integrated it
directly into the housing of the Fortis HD,
so it does not require any additional space.
Kern Fortis HD in a nutshell
→ footprint: L x W x H: 4.07 m (13 ft) x
3.05 m (10 ft) x 3.48 m (11 ft)
→ axis travel: X = 780 mm (31 ’’),
Y = 420 mm (17 ’’), Z = 450 mm (18 ’’)
→ part size (max): 565 mm (22 ’’) diameter,
350 mm (14 ’’) height
→ CSC (Compact Shaft Cooling) tool spindle:
HSK E40 for tools up to 70 mm (2.75 ’’)
in diameter and 245 mm (10 ’’) in length
→ or HSK A63 for tools up to 190 mm (7.5 ’’)
in diameter and 390 mm (15 ’’) in length
→ X-, Y- and Z-axis: direct drives
with micro-gap hydrostatics
→ B- and C-axis:
torque drives with rolling bearings
→ advanced active temperature management
in all linear axes, rotary/swivel axes, drive,
machine base and spindle
→ Heidenhain control TNC 7
The large workspace of the Kern Fortis HD provides approximately twice
the travel distances compared to the Kern Micro HD, which means parts
with a diameter of up to 565 mm (22 ’’) and a height of 350 mm (14 ’’)
can be machined easily
Highest productivity and cutting performance
In addition to the demanding adaptations to the changed dimensions, project
manager Maier and his team have also implemented some completely new
approaches. For example they considered the higher chip volume of the new
machining center. The axes are completely enclosed and are thus very well
protected. With a new design of the machining room, scraper belt conveyors
and a belt filter system are used to reliably remove the chips.
Of particular interest to the operator: the Fortis HD now has a two-part
access door that can be slid open to the left and right side. This makes it
easier for the operator to load and set up the machine and also offers perfect
accessibility and visibility.
As of this year, both machines, the Kern Micro HD and the Fortis HD will
be delivered with the new TNC7 controller from Heidenhain. This ensures
both – best technical stability and user-friendliness. The program structure
corresponds to the usual picture, and existing programs can usually be easily
transferred with only minor adjustments.
Years of testing
Many test runs for customers proved that the new developments in the Kern
Fortis HD are not only theory but also work in the real world. Simon Eickholt
is thrilled: “Several times we received feedback that we achieve better
results with our Fortis after only short run-in phases than our customers
manage with their most precise existing machines. Even though they had
already gone through months of improvements.” Feedback that suggests
high demand and confirms the Kern boss in his basic believe, because: “We
are always very close to the market and our developments are based on the
needs of our customers. Whatever is technologically possible, we do it.”
further information: www.kern-microtechnik.com
no. 4, November 2025
43

components
Precise measurement of hypotubes – despite extremely fine structures
Medical technology: 3D measurement technology
for high-resolution surface analysis
written by RJ Hardt
president of Peak Metrology, a subsidiary of motion control specialist Aerotech
Laser-cut hypotubes (LCHT) have become indispensable
in modern medical technology. The delicate
structures of these extremely thin metal tubes enable
minimally invasive procedures such as catheter ablation,
stent insertion and neurovascular procedures.
However, as miniaturization progresses, the demands
on quality assurance are also increasing. Traditional
inspection methods quickly reach their limits. Innovative
3D measurement technologies open up new possibilities
for detecting even the smallest features while
maintaining high process reliability.
that a data point on the part surface must be generated every
3 to 10 μm. This is the only way to reliably identify even the
smallest deviations.
The smaller the structures, the higher the demands on the
measuring system used. This is particularly true for medical
applications, where absolute reliability is required. Incorrect
cuts, inaccurately placed drill holes or material irregularities
can have serious consequences here – both for the product
and for the patient. That is why precise measurement is an
integral part of every manufacturing process.
The image shows an example of a laser-cut hypotube (LCHT)
being measured with a digital microscope;
this image was taken at 200x magnification
Simple depth of field – the focal plane lies on the
lower radius of the tube
Simple depth of field – the focal plane is at the
upper edge of the tube
An image of the laser-cut hypotube (LCHT)
with the testing equipment used
Why high resolution is crucial
Hypotubes have fine cuts and bores that give them their flexibility
and functionality. To reliably check their geometry
the measurement resolution must be in the single-digit micrometer
range, and sometimes even more. A proven rule of
thumb: the resolution of the inspection system used should
be three to ten times smaller than the smallest feature to be
measured. For example, if you want to measure a 30 μm feature,
you need a resolution of at least 3 to 10 μm – this means
Fully focused on the tube, created by stacking multiple image
planes; this technique enables more precise application
of the measuring tools
44 no. 4, November 2025

components
2D or 3D? A fundamental decision
Although 2D measurement systems are widely used and quick
to deploy, they reach their limits when it comes to complex,
three-dimensional structures. Especially with cylindrical hypotubes,
whose curved surfaces are difficult to focus on, the
choice of a 3D measuring system is usually unavoidable. It
not only allows for better mapping of curved surface but also
offers a more comprehensive analysis of the spatial structure.
This is because the thin tubes are not flat workpieces, but
complex, often multi-layered structures with variable wall
thicknesses. So the measurement technology must be able to
adapt flexibly to the geometry and material behavior – while
delivering reproducible results. 3D measurement systems do
exactly that: they not only record the X- and Y-coordinates,
but also the height information (Z-axis), thus providing a
complete picture of the part surface under investigation.
defined. A 3D system, on the other hand, captures the entire
topography, ensuring reproducible results.
3D measurement systems also offer decisive advantages
when analyzing possible defects such as dents, scratches or
material adhesions. Where 2D images cannot distinguish
between concavities and convexities, the height information
from the 3D data set provides reliable information about the
type of defect. This makes defect characterization significantly
easier, faster and, above all, more objective.
Modern 3D systems can also be used to analyze functional
characteristics: are the cuts symmetrical? Do the angles of
the drill holes correspond to the design specifications? Is the
cut width within the permitted tolerance? All these questions
can be answered with precise 3D data – either manually or
automatically through software-supported evaluation.
The image shows a 3D laser microscope measuring a cut
in a laser-cut hypotube; the data set generated
maps a complete 3D surface
The image on the left
shows a 2D image of
the pipe surface
On the right, the
3D data allows the
surface to be viewed
from an angle, clearly
showing that the visible
defect is a protrusion.
This can be measured
and compared with the
specifications. In this
case, the determined
defect height is 8.8 mm
The optical 2D image shows a height profile line superimposed
on a laser-cut contour; since a complete 3D data set is available,
reference lines can be defined on the inner walls of the cut
contour and on the top of the tube; the intersections of
these lines enable the tube width to be precisely determined
Advantages of 3D measurement technology
3D measurement systems are particularly useful when geome -
tries deviate from the ideal shape. Beveled cuts or angled
drill holes are often difficult to evaluate using 2D approaches,
as the start and end points of the edges are not clearly
Selecting the right system
When selecting the appropriate 3D measurement system, the
specific application is therefore crucial. Three technologies
have proven themselves in our practice:
■ Confocal microscopes deliver excellent resolution and
great depth of field. They are ideal for high-precision detail
images, but are relatively slow – a measurement of
a few hundred micrometers along the surface can take
up to 30 s. They are therefore only suitable for spot check
measurements or small batch production runs. Their
strengths lies in individual part inspection, product
development and process validation.
no. 4, November 2025
45

components
■ Digital image processing systems such as digital
microscopes are significantly faster and generate
3D data by stacking multiple image planes. They are a
good compromise when speed is more important than
maximum height resolution. They can really show their
advantages in random sampling or quality assurance,
especially when large quantities need to be inspected.
■ Confocal 3D scanning sensors combine high resolution
with fast data acquisition. They provide raw data in the
form of height profiles and enable the analysis of entire
hypotube surfaces. In combination with a high-precision
motion system – such as motion control technology from
Aerotech – experience has shown that highly accurate
and repeatable measurements can be achieved even in
automated production lines. Thanks to their modularity,
such systems can be integrated flexibly into existing
production environments.
A digital 3D microscope that creates depth of field by stacking
images from different focal planes; it works faster than a laser
microscope but does not offer the same range of functions:
it lacks the precise height informationor for example,
that would be required for certain measurements
A concrete example illustrates such systems: in one application
confocal technology was used to measure five cut widths
along a hypotube. This point measurement could be easily
extended to the entire length of the tube – and provide reproducible
results at all times. The software used also enabled automatic
classification of defects and geometric deviations – a
real added value for process and quality control.
Overview summarizing the results of ten separate
measurement runs on the same pipe section; the
repeatability of the measurement (“range”)
was 1.2 µm in the worst case
Software and integration
Even the best measurement technology is of little use if it
cannot be efficiently integrated into existing processes. Precise
3D data acquisition is achieved through the use of highprecision
sensors in combination with motion control technology
from Aerotech. This modularity allows flexible integration
into existing automated manufacturing processes.
The software used supports the automatic evaluation and
classification of defects and geometric deviations, enabling
reliable process control.
3D measurement technology as the
key to quality assurance
The inspection of laser-cut hypotubes is one of the most
demanding tasks in medical technology quality assurance –
and the requirements increase with every micrometer of
minia turization. Modern 3D measurement systems offer the
necessary resolution and flexibility to accurately capture even
complex geometries.
The system used – whether confocal, image-based or sensorbased
– depends on the specific application. A well-thoughtout
overall concept is crucial: from the choice between 2D
and 3D measurement technology and the right technology to
seamless integration into existing manufacturing and evaluation
systems.
Those who opt for 3D at an early stage lay the foundation
for stable, reproducible and efficient processes – and thus
create the basis for future-proof manufacturing in medical
technology.
Individual data set from a 3D measurement sensor with
1 µm resolution; the measurements of the cutting width
at five defined positions are visible
RJ Hardt is president of
Peak Metrology, a subsidiary
of motion control specialist
Aerotech. As a long-standing
engineer at Aerotech he has
extensive experience in the
development of high-precision
measurement technology
solutions for industrial
applications. Peak Metrology bundles this expertise specifically
for the field of surface measurement technology –from sensor
integration to complete machine solutions.
further information: www.aerotech.com
46 no. 4, November 2025

New module for optimizing CAD tool data
components
Since 1978 COSCOM Computer
GmbH has been a leading software company
offering successful products and
services in the field of CNC-based manufacturing
digitalization. As an established
EMO exhibitor, COSCOM was
proud being part of this year’s “AI +
Digitalization” joint stand.
“Explaining our solutions for increasing efficiency
and reducing costs in just a few words
is not easy. In addition to digital process optimization
we also offer IT security solutions
for connecting machine tools, which can help
prevent production downtime due to cyberattacks”,
explains managing director Christian
Erlinger.
COSCOM offers comprehensive solutions
from a single source:
→ digital tool database:
creation of the digital twin without
redundant data storage
→ integration of ERP, CAM, simulation,
and storage systems into the
COSCOM Eco-System
→ cybersecurity, network segmentation
and mobile applications
With an experienced team of process consultants,
sales experts and technicians, EMO visi -
tors had the opportunity to discover new approaches
for optimizing complex CNC machining
processes.
New TCI data preparation module for
intelligent CAD data processing
The COSCOM ToolDIRECTOR VM (=Virtual
Machining) is a modular software solution
that provides comprehensive tool management
support. The first step involves transforming
CAD data from various tool manufacturers
as well as in-house tool designs for
CNC machines to create a digital twin. The
software supports CAD data from numerous
systems such as AutoCAD, Autodesk
Inventor, Dassault Systèmes CATIA V5,
SOLIDWORKS, Siemens NX and many more.
ToolDIRECTOR VM delivers complete data
for machine simulation and collision control
within the digital twin application.
One major challenge for digital twin applications
has been the massive data volume. The
large number of fine geometric details –such
A grooving turning tool before and after data minimization; in this example,
the internal details of the four holes have been removed; the yellow cutting
edge is automatically retained, as this area is relevant for the simulation;
overall, approximately 47 % of triangles and vertices were reduced.
as internal structures – significantly affects application performance. While
some geometries must be retained for collision checking and similar processes,
many details (e.g. the internal structure of a bore) are not essential
for the digital twin. Reducing such fine details leads to data minimization.
This is precisely where the new module, developed by the company in
collaboration with long-term technology partner Spatial Corp comes into
play. The company leverages several Software Development Kits (SDKs) from
Spatial Corp, including the 3D InterOp SDK for reliable CAD data translation.
More recently, the company has integrated the Data Prep add-on to
3D InterOp, which forms the foundation of this breakthrough by enabling
significant data reduction and time savings.
The result: an automatic one-click solution for CAD data simplification
within ToolDIRECTOR VM, specifically in the Tooldata Cooperation
Interface (TCI) – the central interface for graphical data preparation. “With
a single click CAD data can be selectively reduced without losing relevant
information. This allows our customers to save significant time not only in
data preparation but also during tool simulation and collision checks”, summarizes
managing director Knut Mersch, responsible for COSCOM software
development.
The new TCI Data Preparation module was demonstrated live for the first
time at EMO at the Spatial Corp booth and is now available.
further information: www.coscom.de
no. 4, November 2025
47

components
Customized and resource-saving
cooling lubricant microfiltration for every size
With its modular central filter systems (ZFA),
filter manufacturer Vomat from Treuen delivers tailor-made
solutions for the ultra-fine filtration of cooling
lubricants – from compact systems to large-scale
industrial projects. A recent example from southern
Europe shows how flexibly the systems can be adapted
to changes in capacity and processes – while maintaining
maximum resource efficiency.
Absolutely clean grinding oil is essential for economical,
reliable and high-quality tool grinding. Filter manufacturer
Vomat specializes in cleaning cooling lubricants (KSS) to the
highest standard – in an energy- and resource-efficient manner,
flexibly scalable and individually tailored to the requirements
of the metalworking industry. In addition to the compact
individual systems of the FA series, central filter systems
(ZFA) are particularly popular with tool manufacturers and
grinders.
Steffen Strobel, sales manager at Vomat: “A current largescale
project in Southern Europe illustrates what we are
capable of: our technicians installed a central filter system
that centrally supplies several production lines and can still
be easily modified if requirements change. With a maximum
filter capacity of 12,000 liters per minute and a tank volume
of 60,000 liters, this ZFA is one of the largest systems of its
kind in the metalworking industry. This underscores our expertise
in implementing particularly challenging filtration
concepts.”
What makes them special: Vomat ZFA systems consist of
separate modules that can be freely combined as required.
Automated disposal units for recycling
This allows tailor-made system concepts to be implemented
that not only meet current production conditions but can
also be quickly expanded or adapted in response to increasing
or changing capacities. This applies to mediumsized
companies as well as large-scale projects.
The basic modules, such as the ZFA 1200 model with compact
dimensions of 1200 × 1200 × 2200 mm, achieve filter finenesses
of 3 to 5 μm and operate with precise, demand-oriented
full-flow filtration using a backwash process. Dirty and clean
oil are separated 100 %, and no filter additives are required.
Thanks to special design features, clean oil in NAS class 7 is
always available during backwashing.
The cooling technology is designed for each process specifically
– with a control accuracy of ± 0.2 K – and can be operated
either via external condensers or cold water. Energyoptimized
machine supply pumps, automated disposal units
for recyclable materials, and a central PLC control system
with remote control function round off the concept. The
bottom line is that the system concept enables a high degree
of automation with low maintenance requirements.
In addition to the compact
individual systems of the FA series, central filter systems (ZFA)
are particularly popular with tool manufacturers and grinders
The result: significantly longer service life for cooling
lubricants and grinding wheels, less maintenance and energy
consumption and reduced machine downtime. In this way,
Vomat ensures that metalworkers worldwide – from individual
tool grinders to large-scale manufacturers – benefit not only
technically but also economically from state-of-the-art cooling
lubricant microfiltration.
further information: www.vomat.de
48 no. 4, November 2025

components
All eyes on extraction efficiency and ease of use
Telford based oil mist filters manufacturer
Filtermist Limited launched
three brand-new products at EMO 2025.
The first new product ‘F Save’, has been developed
to reduce energy consumption on
Filtermist units used on machines which
aren’t always operational. Filtermist MD,
René Joppi elaborates; “Our research and our
customers’ feedback showed that some machines
are only operational for around 30 %
of the working day. If the Filtermist unit is
kept running the whole time the machine is
switched on, whether it’s needed or not, this
means energy is being used unnecessarily.
Not only does this waste valuable resources
and contribute to the customer’s carbon footprint
it also costs money! We’ve developed a smart system
that involves attaching a sensor to the machine’s coolant
pump which sends a signal to the F Save ‘Hub’. The Hub then
switches the Filtermist unit off if the pump isn’t running.
Our data shows that with this new smart system customers
can reduce their energy usage by up to 80 %! In these cases,
payback can be achieved in as little as just over 3 months.”
“F Save does not require any electrical interfacing with the
machine tool which makes it extremely simple to set up. It
also prevents machine operators from accidentally overriding
the mist extraction, meaning people are always protected
from exposure to harmful airborne oil mist particles.”
Filtermist introduced a brand-new oil mist
filter developed in conjunction with Swedish
sister company Absolent AB. The new unit
has been specifically designed to effectively
capture large volumes of submicron particles
generated in applications that use neat oil.
“This latest offering from Absolent Air Care
Group combines over 80 years of oil mist filtration
expertise from Absolent and Filtermist,
packaged in a compact, lightweight, energy
efficient, plug and play unit which is designed
to be machine-mounted”, comments Graeme
Bell, Filtermist’s global commercial director.
“This is a very interesting addition to the
Group’s product portfolio and we were excited
showing it on our stand at EMO.”
The Filtermist booth also included a brand new portable,
modular stand, designed for a variety of extraction requirements.
“The new low-level stand can easily be moved around
and makes servicing and maintenance simple. It’s also ideal
for grinding applications as it can be specified with a cyclone
pre-filter to remove swarf before it enters the Filtermist unit”,
says Graeme. “The stand has removable panels which offers
customers a choice of aesthetics, and if a customer has machines
which are only used occasionally it means the extraction
unit can be shared across different workstations.”
further information: www.filtermist.com
Proven functionality – individually adapted
RotoClamp from HEMA is a pneumatic clamping
system that, with its two directions of action, enables
a wide range of applications. Specifically designed for
rotary position clamping, it is available in internal and
external clamping versions and is compatible with all
common industry shaft sizes. But what if RotoClamp
still does not fit into your machine layout?
Individual adaptation to specific requirements
HEMA’s customized adaptations enable the integration of
RotoClamp clamping systems into any production machine
with rotating guides or drives. After proper testing, customized
mounting, or connection hole patterns, as well as
housing shape modifications, are possible if the specific requirements
of a machine assembly space require them. HEMA
also implements alternative positioning of the pneumatic
connection and customized series with clamping diameters
different from standard products. The functional principle of
the RotoClamp remains unchanged despite all possible adaptations.
In the spring-loaded mechanism a spring diaphragm
is pressurized with compressed air; this shortens it while the
clamping elements release the shaft. When the compressed air
is removed, the spring plates at once return to their original
position and clamp the shaft with great force. A booster function
and additional compressed air supply can further increase
the clamping force. The fail-safe function: if the pneu -
matic system fails, the axis is at once clamped with great force.
Users benefit from process advantages
RotoClamp offers users several process advantages with customized
adaptations for most machine concepts. The pneumatic
system generates high clamping forces even at low pressures,
ensuring high production reliability in precision manufacturing.
The fail-safe function provides additional safety
and minimizes scrap. A cost-effective solution that eliminates
operating and maintenance costs of a hydraulic system.
further information: www.hema-group.com
no. 4, November 2025
49

components
Soft Jaw Designer free for
Fusion and Mastercam user
CloudNC, the manufacturing technology company,
announced that its Soft Jaw Designer plug-in is now
completely free for all users of Autodesk Fusion and
Mastercam.
Soft jaws – custom aluminum or steel inserts used to grip deli -
cate or complex parts so they can be machined – typically
take machinists 30–60 min. per set-up to model manually.
Soft Jaw Designer collapses that work into a few clicks: users
position two blanks around the part model, select Generate,
and seconds later receive complete soft jaw designs ready for
machining.
Theo Saville, co-founder and CEO of the company, said:
“Fixture design shouldn’t keep a spindle idle. By making Soft
Jaw Designer free, we’re putting instant, machinable fixturing
in every programmer’s toolbox – accelerating their output
and helping them focus on tasks that move the needle, while
giving a small glimpse into how much time CloudNC technology
can save machinists.”
Once installed, the plug-in transforms fixture creation.
Instead of multiple sketches, booleans and clearance checks,
programmers simply outline where the jaws should grip.
Soft Jaw Designer then creates the soft jaws – cutting negative
geometry, adding precision allowances and drilling
corner relief – all while keeping the model fully editable. In
real-world testing this reduces the time spent designing soft
jaws by up to 90 %.
Soft Jaw Designer pairs seamlessly with the company’s
CAM Assist. After generating the jaws users can hand the
model to CAM Assist, which automatically creates toolpaths
for both jaws and part, pushing the assembly to the machine
in minutes and further accelerating delivery.
further information: www.cloudnc.com
More capacity. More confidence. Less changeout.
With more choices now available, Eaton’s
MAX-LOAD PEXL pleated filter bags give industrial
processors a smarter way to cut downtime and
improve filtration performance. The enhanced MAX-
LOAD PEXL range benefits from a fully welded polyester
design that provides broad chemical compatibility
and minimal contamination risk. Built for the
toughest jobs, the filter bags feature thermo-bonded
seams and a smooth outer cage that allow for bypassfree
operation and efficient maintenance processes.
At the heart of this innovation is Eaton’s pleated media structure,
which offers up to four times more surface area – and
up to 10 times more dirt-holding capacity – than standard
needle felt bags. This allows for longer runtimes, fewer disruptions
and strong performance across a wide range of
industrial processes.
“Whether it’s a heavily loaded chemical stream, a hot partswashing
line or a condensate loop, the expanded MAX-
LOAD PEXL range gives processors the confidence that
their filtration can handle the job”, said Wim Callaert, senior
product manager at Eaton’s Filtration division. “The use of poly -
ester media provides excellent resistance to acids, alkalis and
mineral-oil-based fluids, and that’s why it’s often the go-to
for elevated temperature environments where polypropylene
would fall short. It’s about giving operators a scalable solution
that withstands mechanical and thermal stress without
breaking down or bypassing.”
Designed to fit Eaton standard size 01 and 02 housings
and backed by the patented SENTINEL® seal ring for true
bypass-free performance, MAX-LOAD PEXL filter bags are
available in multiple nominal retention ratings from 1 to 50
microns.
With proven durability at temperatures up to 275 ° F
(135 ° C) and excellent resistance to aggressive fluids and turbulent
flow, the filter bags are made for demanding filtration
setups. In systems where dirt load is high and maintenance
windows are limited, they offer a longer-lasting, more capable
alternative to conventional needle felt.
further information: www.eaton.com
50 no. 4, November 2025

impressum
ISSN 2628-5444
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Aerotech, Inc. ...................... 44
CECIMO ...........................23
CloudNC ...........................50
COSCOM Computer GmbH ..........47
DMG MORI ....................... 40
DN Solutions. . . . . . . . . . . . . . . . . . . . . . . 20
Eaton. ..............................50
EMAG GmbH .......................31
EMO MILANO. . . . . . . . . . . . . . . . . . . . . .22
EMUGE-Werk Richard Glimpel
GmbH & Co. KG ....................8
FANUC Deutschland GmbH ..........38
Filtermist Limited ...................49
Fritz Studer AG .....................34
Gebr. Heller Maschinenfabrik
GmbH ............................36
Gühring KG ........................15
Hartmetall-Werkzeugfabrik
Paul Horn GmbH ..................10
HEMA Maschinen- und
Apparateschutz GmbH. . . . . . . . . . . . . .49
company finder
IMA Schelling Group GmbH ..........18
IMTEX 2027 ........................22
KAPP GmbH & Co. KG ..............37
Kellenberger Systems. . . . . . . . . . . . . . . . .41
KERN Microtechnik GmbH ......... 42
Lach Diamant Jakob Lach
GmbH & Co. KG ............... 12, 25
Liebherr-Verzahntechnik GmbH. ..... 24
LMT Tools GmbH & Co. KG. ..........11
MAPAL Fabrik für Präzisionswerkzeuge
Dr. Kress KG .................. 16, 26
MAZAK CORPORATION ...........35
Mitsubishi Electric Europe B.V. .........6
Schwäbische Werkzeugmaschinen
GmbH ............................18
Sorma S.p.A. ........................21
Sunnen Products Company ...........32
ultraTEC innovation GmbH. ..........30
UNITED MACHINING SOLUTIONS.. 33
VOLLMER WERKE Maschinenfabrik
GmbH. .............................29
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Hyperion
Materials & Technologies, Inc. ........9
Vomat GmbH. ..................... 48
Walter AG. .........................15
IFR International Federation
of Robotics ........................19
Walter Maschinenbau GmbH. .........39
advertising index
Aerotech, Inc ............................................................page 9
Mitsubishi Electric Europe B.V. .............................................cover
Lach Diamant Jakob Lach GmbH & Co. KG ....................... inside front cover
no. 4, November 2025
51

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