Techno, a computer numerically controlled (CNC) router systems provider, has announced that it will be introducing its CNC router to consumers in the UK.

The company, which has been manufacturing CNC router products since 1986, is offering the 2m x 3m CE certified LC series CNC router together with 5HP high frequency HSD spindle and the supporting software, inclusive of all freight duties for £21,000. The company also aims to provide free technical assistance and online upgrades for the systems.

According to the company, the offer will feature a 2m x 3m LC series CNC router with precision ball screws on all three axes driven with state-of-the-art closed-loop servomotors. The drives have been designed to enable constant position feedback, increased accuracy, and the power needed to route a variety of materials.

Techno says that the system is based on computer software and CNC controller electronics that operate a mechanical device. The company claims that such a system offers greater accuracy and precision compared to a manually operated device, which is susceptible to human errors.

The company claims a basic CNC router can trim edges and cut surfaces in three directions, enabling the user to carve complex shapes. Once a design is fed into the computer, the CNC controller and the computer software work as the memory and command centre for the system, enabling it to move or cut in a particular direction for a certain amount of time.

The CNC router systems accept designs in digital formats, such as a dxf drawing. Users can then combine the CNC controller software with CAM software to convert a 3D or 2D image into a code. These commands are then converted into digital signals by the computer, which are then relayed to the controller. The controller changes these commands into currents that control the mechanical device.

http://www.cbronline.com/article_news.asp

Machining large sheets of material or oversized flat parts can prove challenging for today’s manufacturers and contract machine shops. The sheer size of the material requires a large-capacity machine, but the work itself usually requires high speed, rather than heavy milling.

The new SR-200 Sheet Router from Haas Automation, Inc., is an affordable solution that provides expansive capacity in a lighter-weight, gantry-style, 3-axis CNC machine with 148″ x 76″ x 8″ (xyz) travels. It easily accommodates 6′ x 12′ sheets of material, and accepts ISO standard G-code programming through the user-friendly, full-function Haas CNC control.

The router comes equipped with a 24,000-rpm, 5-hp (continuous) 30-taper spindle for cutting and drilling various plastics, sheet metals and other light materials. An optional 10-pocket automatic tool changer is available for unattended operation using multiple tools. Other high-productivity options include high-speed machining with look-ahead, a hard disc drive with Ethernet interface, a remote jog handle and full 4th-axis capability.

The open-frame design of the SR-200’s steel-beam base allows users to design their own table and fixturing specifically to meet their individual needs (a 1″ thick MDF table is standard). The overhead gantry assembly travels the full length of the fixed table on precision, low-friction linear guides, resulting in extremely accurate positioning. Powerful brushless servomotors on all axes produce high-speed rapids (up to 2,000 ipm in X and Y) for fast cycle times. The standard configuration includes a 15″ color LCD monitor and USB port.

The Haas SR-200 offers specialty shops and manufacturers a highly flexible, easily customized machine of exceptional quality and value. As with all Haas products, it’s backed by the worldwide network of Haas Factory Outlets, offering the industry’s best local service and support

http://news.thomasnet.com/fullstory/538430

ABBA Ball Linear Guides are suited for use in CNC Routers, pick-n-place gantries, screen print machinery, laser cutting machinery, packaging machinery, and automated robotics. Guides are size interchangeable with all international standard dimension linear guides. Corrosion resistant coating is available for food, beverage, pharmaceutical, and semiconductor industries.

08/01/06 - International Distribution Alliance, Inc. (IDA, Inc.) is pleased to introduce the ABBA Ball Linear Guides. Available with a variety of options, the ABBA Ball Linear Guides are an excellent choice for a variety of linear motion applications such as: CNC Routers, pick-n-place gantries, screen print machinery, laser cutting machinery, packaging machinery, and automated robotics.

Outstanding features include:

o Patented internal lubrication forguaranteed longer life and less maintenance

o Size interchangeable with all international standard dimension linear guides

o Wash-down, FDA approved, corrosion resistant coating available for food, beverage, pharmaceutical and semiconductor industries!

IDA, Inc. maintains stock of ABBA Ball Linear Guides for fast delivery.

http://findarticles.com/p/articles/mi_m0PIL/is_2006_August_7/ai_n16610529

Australian Dust Control has worked extensively in the furniture and timber industry.

Australian Dust Control has a commitment to their customers to save them energy consumption and minimise their waste whilst at the same time helping the environment.

Brooker Furniture, a solid timber furniture manufacturer commissioned Australian Dust Control to design and install a Shaker Dust Collector.

The Shaker Dust Collector was fitted with a 15kw fan.

Brooker Furniture was upgrading its operation with the installation of a new CNC Router.

The Shaker Dust Collector replaced its old cyclone dust collector which was inadequate for the new application.

The waste produced in the manufacturing process is wood shavings and sanding dust which is discharged directly from the Shaker Dust Collector to a 3 cubic metre waste bin.

The installation of the Shaker Dust Collector by Australian Dust Control complies with all OH&S regulations therefore providing a safe and clean working environment.

http://www.ferret.com.au/

Tishler Industries, St. Louis, Missouri, has recently installed a new Haas GR 510 CNC Router.

The company, which fabricates medium to heavy welded plate products, purchased the new router to improve the company’s efficiency.

“The new router will help shorten our lead times, allow us to have more control over our schedules and help improve product quality,” stated Doug Schneider, manufacturing engineer. “One of the main factors in choosing the Haas model was the local service available here in St. Louis.”

The Haas GR 510 features: a high-torque 5,000-rpm spindle; a 20-tool changer; a rigid tapping fixture; a thread mill for larger holes and a 5′ x 10′ table. It is currently set to operate with a vise, chuck or an open table setup. Work can be done in any of these configurations without having to change the machine’s setup.
This new equipment is another example of Tishler’s ongoing efforts to improve our processes,” noted Brian Payne, general manager.

Tishler Industries, founded in 1990, started out making tanks and containers for the utilities industries. Today, it handles all phases of projects involving metal plate tanks and containers including design, engineering, prototyping, fabricating and finishing.

The company is a business unit of Gate City Steel Group, Indianapolis, Indiana.

http://findarticles.com/p/articles/mi_qa3698/is_200404/ai_n9394890

A manufacturer of personal care products is saving money and reducing time to market by switching to a low-cost computerized numerical control (CNC) router that makes it possible to produce point of purchase displays internally. When contract manufacturers produced Kiss Products’ displays, there were delays in getting new designs to retailers and the cost of producing the displays was continually rising. Kiss made the decision to make their own displays and the company searched for an inexpensive and easy to use new router that provides the ability to produce plastic and wood components to high levels of accuracy. “With the router we can now design and begin to produce new display designs in a single day,” said Mike Llewellyn, Shop Supervisor for Kiss Products. “The router has features normally found in more expensive machines like ball screws and servo motors that make itpossible to produce a very professional looking product. We could afford a more expensive machine but we don’t believe in throwing our money around. We are saving money and we can now turn on a dime to meet the changing requirements of the retail market.” Ball screws have a number of advantages over racks. They don’t have the play or the requirement for adjustments that racks do, they also do not wear as easily as racks do and they are far less likely to get debris in the mechanism than racks to cause skipping and errant motion. Servomotors, unlike stepper motors do not “lose position” and cannot skip steps. Servos are also far better for 3D applications because they can change speed on the fly without losing power as steppers do.

Kiss is the world’s largest manufacturer and distributor of professional quality nail products. The company originated in the lucrative beauty supply market. As the popularity of the products soared, distribution was quickly expanded to the mass-market arena. Capitalizing on this success, Kiss became the first company to bring professional nail care directly to the consumer, creating easy-to-use, all-in-one kits that make it possible to achieve salon results at home. Today, the Kiss line of professional products has expanded to include nail care, nail color, nail jewelry, nail art, and pedicure products. More recently, Kiss launched its second brand, called Broadway to allow women to achieve salon-like manicures at home, quickly and easily. Each of these ingenious products originated from Kiss’s innovative thinking and vast salon experience. Kiss Products Inc. is located in New York just 20 miles outside of New York City on the exclusive north shore of Long Island.

Displays were outsourced in the past

The company’s products are manufactured in Kiss Products’ factory, then

shipped to its Long Island facility where they are packaged. The company ships them to retailers with displays made of acrylic sheets that hold the individual products. The displays range from approximately 9 inches high, 8 inches wide and 8 inches deep to as much as 24 inches high by 12 inches wide and 8 inches deep and have either two or three tiers of shelves. The product is placed loose in the shelves and shelves are tilted backwards slightly so they don’t fall out. The shelves are held to the walls with acrylic solvents. The company frequently develops new styles of displays in order to accommodate a new product or promotion. In the past, some of these displays were built by subcontractors. One problem with this approach was that a considerable amount of back and forth was required in order explain the company’s concept for the display; get the initial prototypes right and then go into production. Another problem was that the cost of producing the displays was continually increasing.

Kiss’s local operation, called JC Solutions, had considered for some time the possibility of producing the displays internally but was unable to find a manufacturing method that met the company’s cost and quality requirements. “We first bought a table saw and a band saw but we didn’t like the results we were seeing,” Llewellyn said. “The cut edges are displayed when the displays are assembled and the ones we were making were much too rough. We also had a lot of difficulty holding the tight tolerances that are needed to make a professional-looking display. The quality and appearance of the finished product depended on the ability and attention of the saw operator so the shelves produced by this method often just weren’t right. We were looking for CNC routers but the ones that we had seen were either expensive and complicated machines that cost $30,000 or so which was more than we could justify for this application. On the other hand, we also saw a lot of inexpensive routers but it was hard to believe that the light weight frames, the looseness of their rack and pinion drives and loss of position associated with steppers would produce the quality and accuracy we were looking for.”

Then Llewellyn heard about Techno’s new low cost LC series CNC routing system. This machine provides a number of critical features that allow it to deliver accuracy to a level that has previously only been available from machines at a much higher cost. Ball screws are provided on all three axes, offering smooth motion, a high level of accuracy and repeatability, and minimal maintenance. A closed loop servo control system provides constant position feedback, higher power, and smooth continuous motion that eliminates the possibility of losing position in the middle of a part. The LC series machine includes a heavy steel ground stress relieved base and an aluminum T-slot table that can be easily converted to a vacuum table by installing the Techno vacuum table accessory kit. The machine comes fully assembled and includes Techno’s Windows-based CNC G-code interface with free lifetime software upgrades. The new machine is available in three sizes, with work envelopes of 30 by 24 inches, 50 by 48 inches and 50 by 96 inches. Each of these models provides a repeatability of 0.001 inches, a resolution of 0.0002 inches and a maximum speed of 250 inches per minutes. A wide range of optional equipment is offered including a laser scanning module, CNC lathe attachment, Porter Cable router, vacuum blower, and fourth axis rotary table. Best of all, the 4-foot by 8-foot model sells for only $13,995, a fraction of the cost of purchasing this capability just a year ago.

New in-house manufacturing workflow

“The Techno LC machine was the only one that had all the technical features needed to produce the quality we were looking for at a price we could afford,” Llewellyn said. “Techno worked with us to help us get our process right for producing the displays for the new machine. Leon Moy, in particular, provided a great deal of help in specifying tooling and accessories for the machine and helping us get up and running.” To begin with, the company’s designer creates a CAD drawing of a new display. The CAD drawing is then reviewed by the general manager of the company who reviews it and turns it back to the designer. The designer makes any necessary changes to the design, then he graphically nests the individual pieces required to make the display onto a 4 foot by 8 foot acrylic sheet and saves the resulting drawing onto a CD. Mitchell Cruz, the CNC operator, generates toolpaths, makes adjustments to compensate for the thickness of the sheet and creates a CNC program for producing the parts. He loads a new sheet onto the router, secures it with vacuum clamp to the table, uploads the program into the machine control and with the click of the mouse starts the machine. The machine then establishes the zero point for the Z-Axis, and then runs by itself for 30 to 120 minutes, producing enough parts for as many displays as is possible to nest onto an acrylic sheet. The operator, in the mean time, is able to walk away and perform other tasks while the machine is running. For example, he might spend the time flaming parts that were produced previously or breaking-up the acrylic left over from the machining operation which the company sells for scrap.

When the machining operation is finished, the operator then removes the pieces and then applies a torch to flame the cut edges to produce a glossy finish. Then he delivers to the pieces to the assembly department where operators put them together by applying acrylic solvent with a syringe. “The higher accuracy of the new machines means that every piece comes out perfectly,” Llewellyn said. “The accuracy of cutting enabled us to develop a tab and slot construction in some of our displays which overcame some of the difficulties that assemblers were having in alignment of walls and partitions and provided better positioning in line bending. The new machine is also much faster than the power tools that we have tried in the past. The fact that it works without operator attention is another important advantage. Getting all these capabilities for such a low price means that we can now move the entire display manufacturing process in-house with all the advantages that that entails. The time required to respond to market trends by creating new displays has been cut to a fraction of what was required in the past. In fact, on several occasions we have come up with an idea for a new display in the morning and had several built and assembled by the end of the day. Building our own displays also makes it much easier to respond to special requests from customers. And, of course, the money that we save in contract manufacturing costs goes a long way to helping us stay competitive in this low-margin business.”

http://www.techno-isel.com/cnc_routers/Testimonials/Articles/JCSolutions.htm

KMT Robotic Solutions Inc. introduced today the RoboTrim® RT-1200 - a cost-effective, turnkey robotic router trimming system that provides plastics and composite manufacturers with a flexible and reliable means to trim large parts. The RT-1200 system provides more than 75 percent higher throughput than traditional 5-axis CNC’s (depending on the number of tool changes required), enabling it to produce more quality parts per hour.

“The system’s 12-foot rotating wall, larger KMT AccuTrim® R-110 robots and increased spindle capacity enable it to trim the types of heavy plastic, fiberglass and composite parts that are too large to be processed on a RoboTrim RT-1000,” said Chris Lutz, vice president of sales.

The RT-1200 standard model features two riser-mounted KMT AccuTrim R-110 robots inside a steel enclosure. The system’s two-sided 12-foot rotating table can support up to 1000 pounds on each side and accommodate part sizes up to 9 feet long and 2 feet wide. The two position table allows for higher throughput by giving operators the ability to load or unload parts on the outside of the cell while the robot is trimming on the inside. The RT-1200’s ergonomic design keeps the Cycle Start, Emergency Stop and other operator controls within easy reach, while the system’s light curtains and other standard safety features keep the operator out of harms way. KMT’s RouterWare® software saves valuable time by simplifying the programming process, while FANUC’s Collision Guard software saves money by protecting the robot and fixture in the event of a collision.

Manufacturers also have the ability to customize the RoboTrim RT-1200 system to meet their needs. A variety of spindle sizes and options (automatic tool change, single and double-ended) are available to ensure the desired cut quality and cycle time. Software packages like KMT’s System Calibration Tools enable users to quickly and accurately achieve process repeatability and provide a convenient means to transfer programs from one robot to another with little touch up. KMT’s RouterVac® vacuum system keeps the trimming area clean and holds parts securely to the fixture for better trimming results. KMT also offers part programming services and specialized robot and process training.

KMT Robotic Solutions was formed in December of 2006 with the union of KMT Cutting Systems in Ronneby, Sweden and Robotic Production Technology in Auburn Hills, Mich. KMT Robotic Solutions has more than 1500 systems installed around the world and more than 30 years experience developing, designing, building, servicing and supporting robotic automation solutions for manufacturing customers. With locations in Europe, the US and China, KMT is strategically positioned to serve the global market.

http://news.thomasnet.com/fullstory/536424

KMT Robotic Solutions Inc. has introduced the RoboTrim RT-1002 – the latest in KMT’s line of cost-effective, turnkey robotic router trimming systems that help thermoformers, plastics molders and composite manufacturers increase throughput, uptime and employee safety.

“The RoboTrim RT-1002 system not only trims parts more than 50 percent faster than traditional five axis CNC’s, but also offers substantial trimming flexibility, saving manufacturers valuable time and money,” said Routing Systems Sales Manager Paul Schuch. “The ergonomic design improves employee safety by distancing operators from the potentially harmful trimming environment.”

The RT-1002 standard model features a KMT AccuTrim R-44 robot mounted inside a steel enclosure. The system’s two-sided rotating table has a 1000 pound part and fixture capacity and can rotate a 3 foot by 5 foot (and sometimes longer and narrower) part into and out of the cell in less than three seconds. This allows finished parts to be safely unloaded by the operator while unfinished parts are being trimmed inside the cell. KMT’s application-specific software tools and FANUC Robotics’ iPendant teach pendant simplify the part programming process.

The RoboTrim RT-1002 can be customized to meet manufacturers’ specific trimming needs. Adding a second robot or the automatic tool change option will reduce cycle time and add even greater part size and trimming flexibility. KMT’s patented compliant knife can be incorporated into the tool change to turn the system from a router trimming solution into a deflashing cell. KMT’s RouterVac™ high-volume vacuum system improves part quality by holding the part securely to the fixture and removing chips from the trimming area.

With KMT’s TrimPro software, users can create programs offline, build virtual work cells, and simulate and optimize the cycle times of existing cells without building a prototype or bringing the system down from production.

http://www.e-composites.com/frontend/newspage.aspx?sno=4203

Diversified Machine Systems (DMS) manufactures and distributes custom-designed routers for a slew of different cutting applications. One of DMS’ main product lines is a five-axis CNC router that is available in four main styles.

Recently, DMS started searching for a new cable supplier for its five-axis routers. The cables employed on similar machines were breaking and causing downtime for end users. The company needed cables that could withstand heavy-duty applications and at the same time possess high flexibility.

DMS’ search came to an end when it discovered Igus Inc.’s line of Chainflex continuous flex cables. Chainflex eliminated the cable breakage some end-users were experiencing.

DMS employs three different types of Chainflex cable in its routers. Chainflex CF11, a data encoder cable, is used to transmit data signals to different parts of the router. Chainflex CF31 is used to supply power to the motor, while Chainflex CF140US is used for power on larger motors.

Mike Grover, a field engineer with DMS, vouched for the performance of Chainflex cables. “We needed a flexible and heavy-duty cable. Chainflex was by far the best when looking at quality versus price,” said Grover. “We have reduced maintenance and downtime for our customers because of the flexibility of igus cables.”

Grover also noted the benefits of Chainflex extend to both DMS and the end user. “As of yet, we haven’t been in the field to replace Chainflex and our customers are enjoying the worry-free operation of our machines.”

Diversified Machine Systems (DMS) uses three different types of
Chainflex continuous-flex cables on its five-axis routers.

Igus, Inc.

LINEAR ACTUATORS

The 35000 series (Size 14) double stack hybrid linear actuators occupy a minimal 35mm square space and include numerous patented innovations that provide high performance, and endurance and new linear motion design opportunities in a small package. The 35000 series actuators are available in three designs — captive, non-captive and external linear versions. They are available in a wide variety of resolutions ranging from .0158mm to .127mm per step and deliver thrust voluntarily limited to 222 N to avoid compromising long life. These models can also be microstepped for even finer resolution.

Haydon Switch & Instrument, Inc.

AC DRIVE

The new X5 UltraFlex AC Drive is easy to setup and maintain. It offers horsepower range up to 200 HP and features a real-time clock, support for most popular communication protocols, encoder feedback capabilities and a USB port.

TB Wood’s Incorporated

ROLLER BEARINGS

The new series of NKE single row cylindrical roller bearings are used in pumps and compressors, mechanical presses, electric motors, gearboxes, traction motors and axle bearings for railway vehicles, in steelworks and many other industrial applications. They are available in 164 sizes in design variants NU, NJ and NUP. The bearing cages are available in roller-guided and outer ring-guided versions and are made from brass and polyamide, with pressed steel versions available soon. In addition to radial clearance group CN (C0) as standard, C3 and C4 groups are also available.

Global Bear Inc.

LUBRICATION SYSTEM

The Quicklub® System reduces downtime and provides an effective method of centralizing and/or automating the lubrication of critical machine bearings. FLO provides Custom Kits to cover virtually any quantity of points desired or pre-assembled kits to service up to 12 points from a single grease fitting. The basic Quicklub® kit is a centralized system dispensing lubricant manually from a lever gun. The heart of the system is a positive displacement metering valve dispensing metered amounts of lubricants to each point covered by the system. Quicklub® systems can be fully automated using one of a wide range of 12VDC, 24VDC or 120VDC electric or pneumatic pumps.

FLO Components Ltd.

PLASTIC BEARINGS

Iglide® H370 plastic bearings are specially designed for wet environments and high-temperature applications. Iglide H370 is unaffected by elements such as moisture, dirt and dust and is maintenance-free, corrosion resistant, UV-resistant and requires no lubrication. In continuous motion, iglide H370 operates within a temperature range of ­40 to 392°F. With a moisture absorption rating of 0.0%, iglide H370 remains impervious to factors such as humidity or constant submersion in water. It is ideal for underwater applications, bottle-filling equipment, marine applications, dishwaters and applications requiring frequent washdowns.

Igus, Inc.

PRECISION CLUTCHES

One way clutches are stainless steel with oil-impregnated bronze bearings. These over running spring wrapped type clutches are available for clockwise or counterclockwise direction with shaft sizes from 1/8 to 5/8. Typical applications include unidirectional stepping, automatic flywheel decoupling and backstopping. A variety of slip clutches are available including spring wrapped — a continuous duty clutch for use in tension control and transmission overload protection; adjustable — an intermittent duty clutch for light duty only, not continuous duty; miniature — adjustable continuous duty clutches available in clamp or pin hub types.

Nordex Incorporated

COUPLINGS

These newly updated CD® couplings feature zero backlash precision and high torsional stiffness required in demanding servo motor applications with high reverse loads and positioning requirements. Manufactured of RoHS compliant materials containing no banned substances, these newly improved CD couplings are designed with new clamp style hubs for increased torque capacity on shafts without using keyways. The CD coupling is both torsionally stiff and very durable.

Zero-Max

CONVEYOR SYSTEM

The model KGF-P 2040 belt curve conveyor is designed for smooth product turns and transfer of small and delicate parts. It is also useful where production lines require space saving conveyor configurations. The frame features 10mm T-slotted aluminum construction that has excellent load bearing capacities which allows for the direct mounting of side rails, sensors and other accessories. The compact designed conveyor features a 20mm rolling knife edge, permitting efficient and gentle parts transfer from in-feed to out-feed. The compact center drive is located below the conveyor eliminating external interference.

mk Automation, Inc.

FLEXURED COUPLINGS

Helical offers miniature couplings, u-joints, and machined springs with integrated attachment components. Included are couplings with an unlimited variety of customized ends. All products utilize the HELI-CAL® Flexure. Flexured couplings and u-joints are backlash free and provide constant velocity rotation regardless of misalignment.

Helical Products Company, Inc.

SHAFT COLLAR

The U-Clip shaft collar is a one-piece shaft collar that slides on easily and locks in place when released. In machinery or for static applications, quick release U-Clip shaft collars hold reels and tools in place whether on hardened or non-hardened shafts. U-Clip collars are hand installed. A spring loaded release plate permits easy slide on/off action. The device locks in place when released and with a light pull on the release plate the U-Clip slides off. Six sizes are available for metric shaft diameters: 10, 12, 15, 16, 20 and 22. English sizes are available only in large quantities.

Amacoil, Inc.

DC DRIVES

Sprint offers four quadrant DC drives that use little space and are very energy efficient. The 340XRi, 680XRi and 1220XRi DC drives are designed to regenerate energy back into the mains supply under braking without the need for complex intermediate storage, resistive dumping or additional power bridges. A four quadrant regenerative DC drive is fully controllable in both motoring and braking modes, and conserves the maximum amount of energy. The DC drive package offers other energy efficient improvements.

Sprint Electric

POWERED ROLLER

The 3800 Series roller is designed for use in conveyor systems that transport containers and boxes with individual weights of up to 300 lbs. The roller operates with the drive components located away from the conveyor area, reducing the risk of contamination that may have adverse effects on the drive performance. The 3800 Series’ steel tube has a diameter of 1.9″ and features standard O-rings and standard multi-rib belts. Sealed precision bearings can easily handle speeds of up to 360 feet per minute.

Interroll Corp.

PRECISION BALL BEARINGS

The EZO-SPB bearing has an inside shaft diameter of just .06mm or .0236 in. and an outside diameter of just 2.5mm and a width of 1.0mm. Each ball, and there are five in each race, is smaller than those found in a ball point pen and each is precision ground to an exacting specification to ensure long life at operating speeds of between 142,000 and 160,000 rpm. The bearings are ideal for any miniature motion control product such as medical and dental instruments or any product requiring miniaturization with smooth, quiet operating motion.

SPB-USA

HIGH PRESSURE FITTINGS

Valco’s new 360 um high pressure fitting design permits direct connection to 360 micron OD fused silica, PEEK, stainless, or electroformed nickel tubing without having to use troublesome liners. Because of the fitting’s compact size and fine 2-56 threads, a lead-free connection that seals at pressures well in excess of 20,000 psi can easily be formed with the available manual tool. The fittings are available with a PEEK or stainless nut; the PEEK nut is supplied with a glass-filled PEEK ferrule, while the stainless nut uses a 316 SS ferrule. The ferrule snaps into the nut so that the fitting is “one-piece”, but the ferrule is free to rotate and does not twist the tube as the nut is tightened. A wide range of micron bore sizes are available.

http://www.cienmagazine.com/issues/2007/nov/page8.asp

Ironwood Designs, a San Jose, CA-based designer and manufacturer of wooden gun stocks, has more than tripled since replacing a manual pantograph with a four-axis CNC router.

Made of high-quality hardwoods, Ironwood Designs’ products are purchased by individual gun owners, gun dealers and firearms manufacturers to replace the inexpensive plastic or softwood stocks of many imported military guns such as the FN-FAL and the AK-47. Ironwood Designs also sells a four-piece wooden set that includes the butt stock, pistol grip and an upper and lower hand guard.

Production Bottleneck
As one of the few companies making replacement gun stocks for these weapons, Ironwood Designs has a thriving business. According to Matt Shuster, Ironwood Designs president, a bottleneck in the production process needed to be eliminated before further growth could occur.

For the first step in making a gun stock, Ironwood Designs used a Zuckerman copy lathe to automatically carve a wood block into the desired 3-D profile. The machine cut the block from an over-sized plastic pattern of the gun stock. The pattern and the wood block would spin in tandem while the machine’s cutter carriage and a sander carriage traversed the block, delivering a clean finished piece in 1 to 3 minutes.

This part of the production process, which was handled by an Ironwood Designs employee, needed no improvement. The next step was the problem.

After parts were cut on the Zuckerman machine, they needed further

To make the gun stock, Ironwood Designs uses a Zuckerman copy lathe to automatically carve a wood block into the desired 3-D profile. Next, parts are placed on the Techno four-axis CNC router, which positions and cuts four butt stocks at a time in 3 minutes.
cutting to carve out the inlets where the stock fits into the rifle and areas where parts, such as the swivel and the butt plate, are later attached to the stock. After running the parts through the copy lathe, which was located in the company’s shop, Shuster took them to his home workshop, where he used a manual pantograph to make these additional cuts. The pantograph had four spindles so four parts were cut at once. According to Shuster, it was a back-breaking process that was both slow and inaccurate.

The machine cut with straight flute bits. So although some parts could be done with one pass of the bit, others required three or four bit changes. It took an average of 15 minutes to complete the carving process for four butt stocks. Error was the other problem. Using a pantograph involves manually following a pattern with a stylus. If Shuster’s hand slipped, four parts were damaged at once. He estimates that he had a loss of between 10 and 15 percent due to carving errors. Also, as the pattern eventually wore out, edges of the cuts were less sharp, giving them what Shuster calls a “fuzzy” look. Templates would also get kinks and other irregularities, all of which were transferred to the finished product.

Accuracy and Speed
Shuster says a desire for a faster, more accurate carving process led him to look at other options, including CNC machinery. After visiting a woodworking trade show, Shuster purchased a Techno four-axis machine with a 5-foot by 6-foot table, big enough to handle even the longest butt stocks.

According to Shuster, the Techno CNC router is capable of carving the cutouts in about one-fifth the time it took to do them by hand. The machine also automatically repositions a part and cuts all sides in one operation, enabling it to run unattended.

Shuster says he required a machine with four-axis capability because cuts are needed on all sides. A four-axis machine has dual spindles, one that holds the part and one that holds the cutter. The cutting program directs the x, y, and z motions of the cutter as well as the positioning of the part. After one side has been cut, the part can be rotated, for example, to allow access to the other side.

“With a four-axis machine, repositioning happens automatically, so the cutting goes faster and it’s completely unattended,” Shuster says. Using the four-axis machine, it now takes Ironwood Designs only 3 minutes to cut four butt stocks, compared to 15 minutes needed with the pantograph.

The CNC router is located in the shop near the Zuckerman copy lathe; one employee runs both machines. “We now produce 100 pieces in four hours. Previously that took us two days,” Shuster says.

The quality of the cuts is also improved. “There is less tearing of the wood because the spindle is spinning at 18,000 rpm,” says Shuster. “Also, if a cut is off by 0.010 inch, I can modify the program and easily fix it.

“Now we can produce factory-quality pieces. You can’t distinguish our stocks from the original military production except that we use a higher grade of wood,” he continues.

New Business Opportunities
The combination of higher-quality parts and faster production has led to an increase in business for the company. After finishing a large, 212 year contract for one gun manufacturer, Shuster has now programmed the CNC machine for a new product, replacement stocks for the Belgian FN-FAL rifle.

Designed in the 1950s, this rifle had been out of production for years. But surplus versions are being imported and new ones are being manufactured in the United States from old military specifications. Ironwood Designs now offers replacement parts to manufacturers, who will resell them as accessories. The parts are also sold to smaller gunsmiths who build FN-FALs for customers, as well as to private owners of the rifle who wish to retrofit it with a nicer wooden stock.

In addition to this new product, for which Shuster anticipates a big demand, Shuster says he plans to use the CNC machine for other projects. For example, plans call for offering replacement stocks for common guns, such as hunting rifles, which will be easier to install than those currently available. Most replacement stocks, he explains, come semi-finished, i.e., the sides are carved but not sanded, so tool marks are visible. This requires the gun owner to fit the rifle to the stock, a process than can take hours of filing. Shuster says he plans to cut these stocks on the CNC machine for a level of accuracy that has been previously unavailable. “My kits will be innovative because they give you drop-in fit,” he says.

“We no longer advertise and yet our volume keeps increasing,” says Shuster. “With the four-axis CNC machine, we’re now able to produce replacement stocks for anyone who wants one.”

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