KMF (Precision Sheet Metal) goes lights out with Trumpf laser technology and automation

The two laser cutting machines are a 3 kW Trumpf TruLaser 5030 Fiber and a 3.2 kW TruLaser 3030 L20. These two machines are linked by Trumpf's Trustore 3030 Storage Tower system, which has the capacity to store up to 168 tonnes of sheet material in sheet sizes measuring up to 3,000 mm by 1,500 mm. Material is automatically picked from one of 56 locations and transferred to the laser by a Trumpf LiftMaster Linear Store system. The total cost of the machines and storage systems was in excess of £1.3 million, with a further £1.2 million spent on a 17,000 sq ft extension that also houses a dedicated programming department, as well as a covered goods-in and material loading area. By combining these new laser processing machines with the automation system, KMF has achieved a truly 'lights-out' solution to processing a wide range of materials, including copper, brass and aluminium, together with ferrous and stainless steel sheet. Material thickness ranges from up to 6 mm for copper and brass through to 20 mm for ferrous material. This, combined with maximum axis speeds of up to 235 m/min on the Trulaser 5030 Fiber machine, will lead to much improved productivity when laser cutting sheet, while automation will allow for greater flexibility, in terms of batch size. Initial findings following the installation of the machines show, on thin sheet material, average performance gains of over 130% on 1 mm thick sheet and 188% on 3 mm mild steel, when compared to older technology. With the new installation, KMF is also looking to realise further productivity gains as it develops a dynamic nesting philosophy, supported by Trumpf TruTops programming software. "The productivity savings that will be generated, complemented by Trumpf's forecasted reduction in energy consumption and maintenance requirements, helped make the decision to commit to this level of investment relatively straightforward," says Terry Stanway, KMF's purchasing manager. "The set-up reduction available through the introduction of the universal cutting head (which includes a collision protection feature for all sheet gauges) and the automated nozzle changer and cleaning facility will also provide measureable ROI information from day one." This installation is the latest of an ongoing investment programme that has seen the factory at Newcastle under Lyme increase in size by 30,000 ft2 in the past two years, with the workforce growing from 250 to over 300 in the same period.