Bend, punch, profile

Rofin-Baasel's StarCut Tube Femto (01327 701 100) is one of the first systems to offer cold laser cutting for medical device manufacturing. Manufacturing medical devices from tube stock typically relies on laser fusion cutting, with laser pulse widths in the micro-second range. Even with an optimum set-up, this cutting process is not completely free from burrs or recast inside the tube, requiring post-processing by ultrasound polishing on stainless steel and CoCr. The shape memory alloy nitinol can, in certain instances, be prone to chemical and mechanical damage during post-processing. Image: StarCut Tube Femto is one of the first systems to offer cold laser cutting for medical device manufacturing With femtosecond lasers, however, the only post-processing required is simple ultrasonic cleaning. This improves post-processing efficiency significantly, in particular with such sensitive materials. Bio-absorbable stents are at the heart of numerous research and development activities. But the use of bio-absorbable polymers, such as polylactic acid and polyglycolic acid, has suffered, due to their low melting points. This makes them very difficult to machine with traditional cutting lasers and the resultant heat-affected zone results in unacceptable cut quality. In contrast, femtosecond lasers have already achieved excellent results, with vascular stents showing perfect high precision edge quality. Femtosecond lasers process materials faster than energy can diffuse within the atomic lattice, therefore no heat is transferred to the surrounding material, which, in turn, eliminates any recast and burr. The StarCut Tube Femto integrates a completely innovative, compact laser source, with field-proven high reliability and long-term stability – properties that until now have been hard to find in ultra-fast laser sources, it is claimed. The first StarCut Femto systems are already installed and working at customer sites. Moving up to higher power lasers, and Trumpf (01582 725335) has developed a 2D laser machine for the processing of extra large sheets, up to 16 by 2.5 m. Based on the twin-headed TruLaser 7040, the TruLaser 8000 comes with a range of options. In addition to the 4 by 2.5 m pallet changer, a special large sheet version is available that allows for parallel loading and unloading of sheets up to 12 m long, during production. Image: The TruLaser 8000 is a large machine Two TruFlow models may be specified: a 3.6 kW laser, designed for thin and medium sheet thickness; and a 6 kW version that accommodates all sheet thicknesses and provides the highest level of productivity in fusion cutting. The TruLaser 8000 can be equipped with two lasers for simultaneous cutting. As well as doubling productivity, this option also saves on factory floor space. Moving to more heavy duty profiling needs and ESAB has recently unveiled numerous products. Its m3 Plasma Package is designed for integrating with arc welding and various other robots used in the manufacturing area. The m3 Plasma Package consists of a plasma power source from the m3 series, a flow control system, PT36 torch, as well as a stand-alone CNC control, such as the ESAB Vision 50P, which is fitted with all the intelligence to deliver precision and standard cutting and marking. Intended for retrofitting is ESAB Cutting Systems' new Vision 51R CNC control system, which is available in a number of packages that are drop-on replacements for existing customers using ESAB NCE controllers, as well as other types. ESAB Cutting Systems' new COMBIREX plasma and oxy-fuel profile cutting machine features a high-performance drive system and a precision, heavy duty gantry that provides a solid foundation for accurate cutting over working widths up to 3,500 mm. Combined with an ESAB VISION 51 control system and COLUMBUS programming software, the COMBIREX can be used as the centrepiece of an automated production system, says the company. Image: Combined with an ESAB VISION 51 control system and COLUMBUS programming software, the COMBIREX can be used as the centrepiece of an automated production system, says ESABy Moving to punching technology, LVD has introduced the Strippit PA-Series automatic load/unload system, a compact, cost-effective material handling device retrofitable for Strippit VX, V, and S-Series CNC turret punch presses. The auto load/unload system reduces manual worksheet handling time by as much as 80 per cent and provides efficient processing of materials up to 3.5 mm. Offered in two configurations: Strippit PA-1225 supports sheet sizes up to 2,500 by 1,250 mm; and Strippit PA-1530, which handles materials up to 3,048 by 1,524 mm, with raw material bundle capacities of 25,000 kg (1225 version) and 3,000 kg (1530 version), respectively. Both systems work with minimum sheet sizes of 500 by 1,000 mm. Finally, on the bending scene, new from Bystronic (02476 585114) is the 50T 1,600 mm press brake. The machine is said to be fast in operation and has a small footprint, and marks a return to the small press brake market for Bystronic. The bed length of 1,650 mm is also the distance between frames, so component lengths are not restricted by the depth of the machine's throat. The machine comes complete with euro upper tools, quick to change single vee lower dies, laser front guards and a Cybelec CNC 60 control. Box item Application round-up [] Earlier this year, subcontractor Ford Component Manufacturing , Monkton, UK, purchased an LVD (01295 676800) Orion 3015 CO2 laser cutting system with 2.5 kW laser source for processing of components for the automotive, power generation, rail, construction and other high-tech industries. Orion 3015 is a compact, hybrid-style laser cutting system, able to process sheet sizes up to 3,000 by 1,500 mm and up to 16 mm mild steel, 10 mm stainless steel and aluminium up to 6 mm thick. [] Bradford-based subcontract fabrication specialist Powell Manufacturing has achieved notably impressive 99.68 per cent uptime since installing its latest TruLaser 3040 laser cutting machine from Trumpf (01582 725335). Powell Manufacturing demanded high uptime guarantees before committing to the purchase of the TruLaser 3040. Powell Manufacturing, (previously known as NGBM), a trading division of Switchgear & Instrumentation Ltd, was acquired by US group Powell Industries in 2005. Although the company continues to supply fabricated products for the switchgear side of its business, around £5 million is generated annually in turnover from external contracts. In its first 97 weeks, the TruLaser 3040 worked for 13,926 hours – 143.54 hours per week. This equates to 99.68% availability across the company's 24 hours a day, six-days-a- week regime (144 hours). Downtime has amounted to just 42 hours in 97 weeks, time that can be attributed to installing new software updates and for routine wearing part changes. [] The installation of a new Salvagnini P4X panel bender (01989 767032) with automated load/unload units at the Loughborough facility of subcontractor JC Metal Works has not only cut cycle times for forming operations by a magnitude of five (or 10 in some instances), that has also had a direct effect on turnover, helping the company generate 80 per cent more revenue. JC Metal Works previously operated three CNC press brakes. "I guess the normal thing for an expanding fabrication business like ours would be to invest in more press brakes without giving it too much thought," says company director Jason Chauhan, who has worked at the family-owned business for the past 11 years. "However, we knew our bigger factory would mean more throughput and more product changeovers. I didn't feel we would be able to compete effectively at this level using press brakes, which can typically take up to 30 minutes to set. We were aware that many of our larger competitors operated panel benders, as we would sometimes lose tenders because we didn't have one." Fist published in Machinery, September 2010