Four high cutting speed routing systems are producing interior components for a sports car manufacturer by triming edges and forming holes and slots in a wide range of polymeric materials.

At the company's plant at Boetzingen in South-West Germany, Peguform is using an installation of four routing systems from KMT Cutting Systems to produce interior components for a Stuttgart-based sports car manufacturer. Routing is the preferred finishing technology for the dashboards, door panels and central consoles that Peguform produces in a state-of-the-art facility that brings together slush moulding, injection moulding, foaming and a range of finishing technologies on the same site. Routing is a dry cut process that utilises an electrically powered routing head with a spindle-mounted bit, which is spun at very high speeds up to 50,000 rev/min to trim edges and form holes and slots in a wide range of polymeric materials.

The method gives a very accurate material separation and produces a high quality cut edge.

Routing can also be used to cut materials to a pre-defined depth which is key to the use of routing in making perforations for air bags.

Of the four KMT routing systems at Peguform, two are dedicated to finishing left and right drive dashboards, two are dedicated to work on driver and passenger side door panels and the fifth is used to rout the central console parts, respectively.

Each of the systems is a self-contained unit meeting all EC machinery safety standards, housed in a low footprint enclosure separating the routing process from the operator and the rest of the plant.

The systems have fixtures mounted vertically on a double sided flip-frame, allowing the operator to unload and load a new part, whilst another is being routed on the flipside inside the enclosure, increasing system productivity.

At the front of the routing enclosure, there is a rolling door which acts as a protection system for the flip frame.

In addition, there is a horizontal light barrier as back-up protection between the rolling door and the flip frame.

The vertical design of the fixture on the flip-frame offers excellent ergonomics for loading parts.

The part is fixed in place by a combination of clamping and vacuum suction.

Sensors mounted on the fixture detect the presence of the part and whether or not it is properly positioned before the routing cycle can begin.

On the dashboard fixtures, there are dedicated sensors feeding the system with measurements of the position of the airbag section, whilst for the door panels, there are sensors to detect whether or not the correct inserts are in place for the side air bag systems.

The routing systems at Peguform are equipped with many of the options available from KMT.

The first of these is a Fixture change unit with which just one operator can change the fixture on the routing systems in under three minutes.

It is an easy system to use that also provides secure and space-saving storage for the fixtures when they are not being used.

Another of the options is a barcode reader that reads the barcode on the part to confirm its identity.

This is then checked through a production control interface also supplied by KMT, which talks to the plant's manufacturing database to ensure that the part on the fixture is approved for routing.

If the database indicates there is a fault, then the routing system is instructed to destroy the part.

As well as overseeing the process, the production control interface also saves a full record, comprising some 85 different parameters, of all activity in the routing boxes to a process data system for download to the manufacturing database.

Normally the part is passed for routing, the rolling door is lowered and the cycle is started from a control panel located outside the box.

When the part is flipped inside the box, it is marked securely with its part number using an optional laser marking system.

The KMT routing stations feature a single IRB 2400/16 M2000 industrial robot from ABB offering a 16kg handling capacity and 0.06mm positional repeatability.

Inside the Box, the 400 lux lighting provides excellent illumination for programming the robot.

The system utilises the renowned Jaeger range of spindles providing high quality performance for this exacting application.

The routing boxes are equipped with tool change stations, allowing tools to be changed while the routing system is in operation.

The optional tool change stations also offer an automatic update of tool parameters through a tool length measuring system that provides an accurate length for each tool in the system.

When installing a new tool on the tool change station, the length is compared to a nominal value and any variance is taken into account when the tool is later used in the routing process, ensuring very high accuracy after each tool change.

The measurement system is also utilised to gauge whether or not there has been a break in the tool, performing measurements at programmed intervals and alerting the system if a tool break occurs.

The system automatically measures a tool after change to ensure that a tool of the right length is loaded, hence avoiding any crash in the system.

The numbers of cycles a tool should be used before it needs to be changed can be programmed into the system to remove the risk to the routing process and the quality of the parts it produces.

The tool change station also includes a Renishaw 3D sensor - system that is used to take 3D measurements in three corners of the air bag system to ensure that the perforations produced by the routing head for the air bag are to the correct tolerances.

As well as good ergonomics, another advantage of the vertical worktable arrangement is that waste material falls by gravity on to a conveyor below the routing area, from where it is transported out of the box into a waste hopper.

In addition, the airborne dust that always accompanies routing is sucked through ducts either side of the worktable, by a high powered air cleaning/filter system that passes the air through filters, before returning the filtered air through floor level vents at the back of the system.

As demonstrated by the systems at Peguform, the routing range from KMT Cutting Systems ensures high position accuracy for the router with very efficient waste disposal.

The systems have a small footprint and are easy to install.

In fact, the systems offer a 'Plug and Produce' capability, allowing them to be started up in just one day, if KMT supplies the fixtures and cutting programs from the beginning.

All the routing systems come with a global support package second to none, providing technical, service and parts coverage in virtually every country in the world.

Applying linear motors to the X-axis movement of each cutting head can allows accurate control by the CNC with a positioning accuracy as fine as 0.05mm using coils fitted to each head.

Water Jet Sweden is believed to be the first manufacturer of waterjet cutting machines to incorporate linear drives in this technology for customers who have discerned the technical advantages of this option. Increasingly already being applied to advanced machine tool designs, linear drive systems are now being taken up by designers of other types of machinery and equipment used in a variety of manufacturing processes throughout the world. In the case of Water Jet Sweden, the close collaboration enjoyed between themselves and CNC suppliers GE Fanuc over recent years has seen the introduction of a linear drive option across the range of profilers produced at the busy Ronneby factory in southern Sweden.

With the entire linear drive system being sourced from the same supplier as the other drives systems on the machine, plus the CNC control, the whole package is totally integrated and thereby offers assured reliability.

* Great accuracy - when applied to a Water Jet Sweden machine, the whole X-axis is fitted with a single flat magnetic plate.

The X-axis movement of each cutting head can then be accurately controlled by the CNC with a positioning accuracy as fine as 0.05mm by means of coils fitted to each head.

Lennart Svensson, managing director of Water Jet Sweden, said: 'As well as the well-known advantages of such a drive system, it is especially useful for multi-head profiling.' He cited the many cases where nested items need to be cut using the 'common line' method whereby the intermediate heads of a multi-head arrangement are cutting a line that forms both an 'inside edge' of one component and the 'outside edge' of its companion, thereby simultaneously eliminating the wasteful 'picture frame skeleton' left in the sheet.

Significantly, because each of the heads can be easily re-positioned independently, it is far quicker to replace any one or more nozzles as wear takes place.

This nozzle wear can be compensated for automatically which is an attractive time-saving proposition in a busy shop.

* Other advantages Such drive systems cannot be affected by that small element of component wear that might occur over long periods of time with other drive systems.

Additionally, there are no backlash or pitch error problems to worry about.

The improved long-term positioning accuracies achievable are an added incentive to adopt the linear approach.

The application of a linear drive system to a waterjet profiler is a good one because, unlike other metal cutting machines, there is no swarf or coolant present that might pose a risk to lifelong performance.

In any case, the X-axis drive is mounted on top of the cross gantry where it is well above the work interface.

It is, therefore, in the field of multi-head, high-volume work that the linear drive option can really prove its worth, especially when the added advantages of increased positioning speed and acceleration while profiling are taken into account.

A guide to the specification of refurbished profile cutting machines describes a refurbishment and retrofit service for any old ESAB, BOC or Hancock gas cutting machines in use.

A guide to the specification of refurbished profile cutting machines has been published by ESAB Automation, the UK's most experienced and established supplier of refurbished machines. Offering a cost effective alternative to investment in a new cutting machine, ESAB Automation has a wide and continuously changing stock of refurbished machines to suit all types of production requirements. Traditionally, the company offers customers a full refurbishment and retrofit service for any old ESAB, BOC or Hancock branded gas cutting machines still in use.

When companies opt to have their own machines refurbished, they can frequently be immediately swapped with an already upgraded machine of similar specification, saving downtime.

All the critical components of refurbished machines available from ESAB Automation's stock have been renewed to enhance performance, safety and accuracy.

All mechanical bearings, control panels, co-ordinate drive mechanisms, cutters, posts and gas hoses are replaced and optical tracing systems are frequently upgraded to include a new control system.

Retrofit of a CNC control gives customers immediate advantages at low initial cost.

Full details of ESAB Automation's Refurbished Cutting Machine Service are available in the 'New Guide to Refurbished Cutting Machines'.

A high performance plasterboard cutter uses high pressure waterjet cutting and linear drive mechanisms to cut lengths of coving with high accuracy and minimal waste.

A world leader in the manufacture and supply of specialised machinery for the worldwide plasterboard cutting industry has come to rely upon waterjet intensifier technology from KMT Waterjet Systems. One of the most recent orders secured by Electronic Control Specialists (ECS) of Heanor, Derbyshire was for its Cove Cutter, destined for a major Australian customer. This high performance cutter uses high pressure waterjet cutting and linear drive mechanisms to cut lengths of coving with high accuracy, which is better than +/-1.5mm, and minimal waste.

The Cove Cutter can achieve line speeds of 85m/min with coving lengths between 1200mm and 16000mm.

For ECS, achieving these performance levels are the result of a combination of the company's own 25 year design experience in plasterboard cutting technology and the advantages achieved by the waterjet cutting process.

Waterjet cutting relies heavily upon the performance of the intensifiers and for managing director Adrian Anthony, KMT Waterjet Systems have always provided the best product: Over the years, ECS has specified KMT (and previously Ingersoll Rand equipment) for many of its specialist plasterboard cutting systems.

'We specify KMT because their intensifiers are of the highest quality, totally reliable and quiet in operation.

The company provides good service back up and we are kept fully informed of product developments and enhancements,' said Anthony.

For the Cove Cutter destined for Australia, ECS specified a KMT Streamline 15HP pump.

This provides the required water pressure to achieve clean, accurate cuts with no noise, waste or dust.

For the customer, this means minimal material wastage and no need for post production trimming operating - resulting in large potential cost savings.

KMT Waterjet Systems' intensifiers are used in a wide a range of general engineering and specialist applications, for many different materials.

ECS recognises that KMT Waterjet Systems' products provide a level of performance for specialist plasterboard cutting machinery not obtainable from inferior, alternative suppliers' products.

Live waterjet-cutting demonstrations on Jet Edge's High Rail Gantry System demonstrate a high-powered intensifier pump, motion controller, and a new digital readout for multi head positioning.

Jet Edge will demonstrate its latest waterjet cutting technologies at the International Manufacturing and Technology Show (IMTS) at McCormick Place in Chicago. During IMTS, Jet Edge sales engineers will conduct live waterjet-cutting demonstrations on Jet Edge's High Rail Gantry System utilizing the high-powered iP60-60 intensifier pump, AquaVision Di motion controller, and the new digital readout for Multi Head Positioning. Jet Edge's waterjet-cutting systems cut nearly any material, from food products to hardened tool steel to titanium.

The company's systems are being used by the world's leading airlines, automotive and aerospace manufacturers as well as industrial manufacturing companies and machine and job shops around the world.

Jet Edge's customers include Ford, Toyota, General Motors, Boeing, American Airlines, and General Electric.

'Our cutting systems have many advantages,' said David Dumas, Jet Edge sales director.

'We are known for our very large work areas and accuracy.

We can hold an accuracy of 0.005in with a repeatability of 0.001in over the entire work envelope'.

'Our cutting systems are powered by hydraulic intensifier pumps that can offer 15,000 to 30,000-plus hours of operation on the hydraulic pump, depending on the model.

This, of course, means greater productivity and lower operating costs.

The cutting systems are controlled by a state-of-the-art AquaVision Di motion controller that guides users through the project step-by-step.' During IMTS, show participants can see for themselves the remarkable versatility and speed of Jet Edge's High Rail Gantry System.

They also can see Jet Edge's new iP60-50 intensifier pump in action.

The 'heart and soul' of the Jet Edge waterjet cutting system, the iP60-50 intensifier pump is rated for 60,000 lb/in2 and features an extended-life hydraulic system.

The iP60-50 intensifier pump provides easy access for all service and maintenance.

It features non-threaded high-pressure components in the high-pressure cylinder, an improved performance check valve, and low torque values.

The Jet Edge iP60-50 intensifier pump leads the industry with ease of operation and low operating cost.

It requires very few tools to maintain.

The cutting system is controlled by the AquaVision Di motion controller that guides users through the process from job set-up to production.

With the AquaVision Di, single parts, part arrays, mirroring, scaling, rotation, and plate alignment are right at users' fingertips.

The AquaVision Di is fully networkable, allowing part programs to be generated offline and easily transferred to the system's hard drive for production.

Feed rate and acceleration are automatically varied, based on known features of a specific job.

Dynamic tool offset, or 'cutter compensation', is employed real-time, and an optional real-time pump control allows remote starting and stopping of the pump, dual pressure set points for piercing hard-to-pierce materials, and unlimited data logging of every process parameter imaginable.

The AquaVision Di includes a full-featured hand-held pendant that allows feed rate override, return-to-path, program zero set points, and XYZ axis control.

Show participants are sure to be impressed by Jet Edge's new Digital Readout for Multi Head Positioning, which improves productivity by reducing setup time.

The Digital Readout for Multi Head Positioning digitally displays cutting head positions, eliminating manual measurement.

It is an excellent addition to your Jet Edge waterjet cutting system.

* About Jet Edge - Jet Edge is a global designer and manufacturer of ultra-high pressure waterjet systems for precision cutting, surface preparation, coating removal, and hydro demolition.

Jet Edge systems are used around the world in a broad range of industries, from the world's leading airlines to automotive, aerospace, industrial manufacturers, machine and job shops.

High amperage high definition plasma-arc cutting and marking system offers expanded thickness capability, optimized cutting speeds and unrivaled cut edge quality.

High power plasma-arc cutting offers quality High amperage high definition plasma-arc cutting and marking system offers expanded thickness capability, optimized cutting speeds and unrivaled cut edge quality. With innovative design features that raise the bar on true precision plasma-arc cut edge squareness and offer unparalleled consumable life, Kaliburn's new Spirit275a system is the company's most advanced cutting system ever. Coupled with its recent unveiling of a new corporate name and brand identity, the introduction of this revolutionary new product marks another significant milestone for the company and solidifies its positioning as a leader in the plasma-arc cutting industry.

This high amperage high definition plasma-arc cutting and marking system from Kaliburn offers expanded thickness capability, optimized cutting speeds and unrivaled cut edge quality.

Through technological advancements, the Spirit275a is designed to deliver virtually dross free cuts with minimal face beveling.

'In the spirit of Kaliburn and our commitment to superior quality, we describe the precision plasma process in traditional terms of minimal cut face bevel,' commented Steven F Hardwick, president of Kaliburn.

'At Kaliburn, we set higher standards for ourselves and manufacture products that deliver uncompromising cut quality for our customers and end users, and we are extremely excited about our new Spirit series,' he added.

Spirit275a is a 275A system that offers production cutting of steel up to 1.1/4in (31mm) thick, with a maximum capacity of 2in (50mm).

This expanded thickness capability plus its optimized cutting speeds, unparalleled consumable life and low operating costs make the Spirit275a the ideal choice for production shops demanding the highest in plasma-arc cutting performance.

Additionally, the system is convenient and easy to use with the Automatic Gas Console (AGC) that automatically sets process parameters, displays the required torch parts and part numbers, and monitors the parts' usable life.

The system is available with the patented Inova torch height control system, which sets all vertical height and arc voltage parameters, further simplifying operation and maximizing versatility and torch consumable life.

The Spirit275a is one of three fully automatic systems in the Spirit series of products.

Other Spirit systems provide identical cut quality and each offer a unique amperage range and corresponding thickness capacity.

In addition, Kaliburn offers three similar systems in a less automated configuration that deliver identical cut quality, but require manual process parameter setting.

These systems are great choices when budgets are limited, yet superior cut quality is necessary.

Established in 1985, Kaliburn (formerly Innerlogic) has flourished from a producer of torch height control products into an industry leading manufacturer of plasma-arc cutting systems.

Headquartered in Charleston, South Carolina, USA, the company is committed to delivering innovative, reliable products backed by unprecedented customer service and product warranties.

Through its significant growth and product advancements, the company continues to evolve and maintain its leadership position in the plasma-arc cutting industry.

Waterjet cutting systems manufacturer offers the IMTS oppurtunity to literally work with the machinery, software, components and products, which are built to be expandable.

WARDJet, a manufacturer of waterjet systems is taking a unique approach to displaying their product at IMTS in 2006. Attendees will have the opportunity to literally work with the machinery, software, components and products. Designed to be functional, practical, easy to service and maintain, WARDJet's waterjets are built to be expandable and grow with users as their businesses flourish.

These multifunctional units come with an inspiring list of options that can be added at any stage, like water-only cutting, laser alignment, drilling and reaming, rotary axis pipe cutting, automatic height sensors and adjustment, wireless pendants, live video monitoring and much more.

Integrated clamping, jig and fixturing allow quick and easy loading, cutting and unloading of parts.

It is clear that WARDJet, when selling off their large job shop division in 2003, took all the knowledge gained and incorporated everything into these sturdy machines.

Plasma-arc cutting system system produces high-speed, low-cost operation; high-quality precision cutting and marking; and high-current, thick-plate cutting - all with a single plasma torch.


ESAB's new m3 Plasma System combines multiple plasma cutting and marking features in a single easy-to-use system, taking plasma cutting productivity to new heights. The m3 system produces high-speed, low-cost standard plasma cutting; high-quality precision cutting and marking; and high-current, thick-plate cutting all with a single plasma torch. When configured for 600A operation, the system can quickly and accurately cut and mark material from 20 SWG to 6.25in (1mm to 160mm) without sacrificing cut quality.

The m3 Plasma System will be on display at IMTS Booth B6157.

The key to this new system is the new state-of-the-art PT-36 torch design.

Instead of setting a fixed cutting current and adjusting other parameters to achieve the desired cutting result, ESAB starts with the desired result and then determines the best parameter settings, including current, needed to achieve it.

This design allows ESAB to achieve superior cutting and marking results over a wide range of materials and thicknesses while using the fewest consumable parts in the industry.

The new PT-36 torch replaces up to three single-purpose torches (heavy plate cutting, precision cutting and marking) and produces a superior cut face with low dross, requiring little secondary clean up.

The end result is superior cutting functionality and productivity, with minimal set-up time, downtime and consumable cost.

The new torch can function in both dry and water injection modes.

The m3 system features the most advanced gas control system in the industry, fully automated by ESAB's Vision CNC.

Great flexibility in selection and mix of shield gases allows an operator to produce the best cut quality on any material.

The operator simply selects the material type and thickness, and the Vision CNC automatically selects and mixes the optimal start, cut and shield gas combination.

Process parameters for most plasma cutting and marking applications are preloaded in the Vision CNC, and custom parameter files can be easily created as needed.

ESAB Welding and Cutting Products is one of the world's largest and most experienced manufacturers of welding and cutting equipment and welding filler metals.

Recognized as the technological leader in the industry, ESAB is committed to providing customized solutions for its customers.

A CNC multi-process waterjet cutting system uses ESAB's patented waterjet/plasma combination to produce cut parts using the speed of plasma-arc and the accuracy of waterjet.

ESAB Cutting Systems will demonstrate the Hydrocut LR multi-process waterjet cutting system at IMTS, Booth B6157. This CNC shape-cutting machine uses ESAB's patented waterjet/plasma combination to produce cut parts using the speed of plasma and the accuracy of waterjet. The waterjet process can also be combined with many other cutting or marking process tools, including oxyfuel cutting, plasma marking, ink-jet marking, routing, drilling or scribing.

The advantage of combining waterjet and plasma on the same machine is that both tools can be used on the same parts.

Contours requiring high precision can be cut with waterjet, while other contours can be cut with plasma.

This system allows users to produce the precision contours they need without sacrificing speed on every cut.

The Hydrocut LR is a precision gantry on floor mounted rails, featuring digital AC drives, brushless AC motors and precision planetary gearboxes.

The machine delivers smooth, accurate motion for the most precise cuts on a wide variety of materials.

Hydrocut LR features positioning accuracy of +/-0.010in over 3ft in each axis, and repeatability of +/-0.002in.

A maximum positioning speed of 600in/min keeps traverse time to a minimum.

Combined with ESAB's high-speed lifters and integrated process control, this speed delivers maximum throughput and low cost per part.

The Hydrocut LR is available with cutting widths of 8ft to 20ft.

It can be equipped with up to four waterjet cutting stations, along with a wide variety of other cutting and marking process tools.

When combined with ESAB's m3 Precision Plasma system, the Hydrocut LR provides the ultimate tool for maximized production and precision cutting.

Automatic height control for both waterjet and plasma processes allows underwater cutting with the waterjet and plasma tools.

This reduces noise, fumes, plasma glare and abrasive spray.

The automatic height control also allows unattended cutting.

Operators can perform other jobs while the Hydrocut LR is working and not worry about the waterjet nozzle or plasma torch crashing.

Large parts can be produced with minimal supervision because the height will remain constant.

The Hydrocut LR can be equipped with waterjet systems from 30 to 100 HP and with plasma systems from 100 to 600A.

ESAB's m3 Precision Plasma system provides high precision cutting on carbon steel, stainless steel, and aluminum from gauge material up to 6in thick.

ESAB Welding and Cutting Products is one of the world's largest and most experienced manufacturers of welding and cutting equipment and welding filler metals.

Recognized as the technological leader in the industry, ESAB is committed to providing customized solutions for its customers.

Programming and nesting software package is designed specifically for plasma, oxyfuel, laser, and waterjet cutting and supports straight and bevel cutting, as well as all current marking devices.

ESAB Cutting Systems will demonstrate its Columbus Programming and Nesting Software at IMTS, Booth B6157. Columbus is an advanced software package designed specifically for plasma, oxyfuel, laser, and waterjet cutting. The first cutting software package developed and maintained by a cutting machine manufacturer, Columbus supports straight and bevel cutting as well as all current marking devices.

At the core of the Columbus system is the Vision PLUS Desktop.

This base module contains numerous functions that conveniently enable the creation of machine programs from geometrical information.

A set of integrated modules can be combined as a seamless package to provide exactly the features and capabilities needed for a given application.

Included with the standard Vision PLUS Desktop is a comprehensive set of modules that provide basic programming capabilities and serve as the foundation for additional optional modules.

The Automatic Nesting module adds fully automated true shape nesting to the Vision PLUS Desktop system, providing Part-In-Part Nesting, Multiple Torch Nesting, Common Line and Bridge Cutting, and many other powerful features.

The user can control all aspects of the nesting process, such as the number of cutting heads to be used, priority of each part in the nest, cutting sequence or material grain limitations.

Parts can also be selected by weight or size to ensure the best optimization possible.

The Data Management Module (DMM) provides part management and tracking capabilities, converting the nesting system into a powerful tool for production control.

Delivery date, material required, and nesting priority of a part can all be specified.

This module allows a user to automatically track the part/order through the entire process and track what plate was used to cut the part.

The Plate Management Module adds plate inventory and remnant tracking capabilities to accurately track plate inventory and utilize every scrap of plate, maximizing profits through maximum plate utilization.

The 3D Transition Programming Software allows quick and easy development of three-dimensional transitions.

Graphical selection of the shape and graphical 3D displays make it easy to create the desired transition.

The software automatically unfolds the 3D shape into a 2D program for cutting.

When used in conjunction with ESAB's Vision PLUS CNC package, Columbus software allows machine operators to post DXF files and draw parts right at the Vision PC or Vision NT controller.

Vision PLUS CNC includes many features that simplify creation of a CNC program from geometrical information.

ESAB Welding and Cutting Products is one of the world's largest and most experienced manufacturers of welding and cutting equipment and welding filler metals.

Recognized as the technological leader in the industry, ESAB is committed to providing customized solutions for its customers.

A large format abrasive waterjet cutting machine for fabrication shops uses direct drive pump technology to cuts parts faster and more accurately than with intensifier pump technology.

Omax is proud to announce the launch of The Fabricator JetMachining Center, the newest addition to its industry-leading line of abrasive waterjet machining products. The Fabricator offers large format abrasive waterjet cutting for stone and tile, and fabrication shops, at an affordable price - and like all Omax machines using their direct drive pump technology, it cuts parts faster and more accurate than conventional waterjet machines using Intensifier pump technology. Perfectly suited for those working with large workpieces, The Fabricator possesses a 4000mm x 2000mm width cutting envelope, with unlimited length expansion available in 2000mm increments.

A 272kg (600lb) abrasive hopper helps to ensure maximum machine utilisation.

The Fabricator uses a single or twin Maxjet 5 nozzle and ultra-high pressure direct drive pump to provide maximum speed and accuracy through high-pressure waterjet cutting.

The machine also achieves a high quality surface finish that reduces or eliminates the need for secondary operations.

Efficiency is further enhanced through the use of the Omax patented intuitive motion control system incorporating Windows XP software.

The Fabricator is capable of machining a broad range of materials including extremely hard, reflective and nonconductive materials and thicknesses.

Compared to traditional machining methods, The Fabricator offers much faster and easier set-ups, with minimal fixturing requirements.

It also cuts without creating heat-affected zones or mechanical stresses in the material being machined.

Like all Omax products, The Fabricator comes with the Omax Technology Guarantee, which provides updated software to all existing customers at no additional charge.

Installation of a waterjet cutting facility equipped with a 50HP intensifier has enabled a ceramic tiles manufacturer to provide even better service and not have to rely on sub-contractors.

As one of the leading importers and distributors of high quality ceramic tiles, Inter Ceramica of Harrogate has an established reputation for providing both standard and customised products for its extensive customer base. The company's decision to invest in its own in-house waterjet cutting facility, including a Powerjet Systems cutting table and KMT Waterjet Systems intensifier, was made in order to provide even better service and not have to rely on outside sub-contractors. The Powerjet Systems 3x2 metre Maxi waterjet cutting table equipped with a KMT 50HP Streamline SL-V pump has proven to be a highly successful investment.

By handling all the cutting in-house the risk of tiles being damaged during transportation has been severely reduced.

It has also given Inter Ceramica more freedom to create new designs and to produce more specials and one-offs.

These value added services are bringing valuable extra customers and income to the company which is already paying back the capital investment.

Powerjet Systems and KMT's joint experience in waterjet cutting of ceramics was important to Inter Ceramica.

They had the opportunity to view other similar installations and see the benefits first hand.

One of the most important of these was the simplicity of the process and the ability of operators able to run the machine after just a few hours training.

Inter Ceramica's installation features off- line programming, Baldor based drive systems and Powerjet's own software.

The KMT Streamline SL-V intensifier is a critical part of the installation.

Its compact design and minimal space requirement means that it can sit conveniently alongside the Maxi table within a dedicated area at Inter Ceramica.

With its plug and play technology the Streamline was easy to integrate with the table.

The pump's reputation for reliability, easy maintenance and lower operating costs were important considerations for Inter Ceramica, who relied upon the experience and know-how of both Powerjet Systems and KMT when considering the investment.

The pump features Klockner Moeller PLC-based control, ceramic plungers and the patented KMT Hard Seal End Cap topwork design.

The installation has been a major success and helped to further enhance Inter Ceramica's already impressive reputation for high quality products and first class service.

With the introduction of dynamic nesting each sheet thickness is only ordered in one size, simplifying the nesting process and making significant savings in labour and work in progress costs.

Finlay Hydrascreens was formed in the late 1950s with the aim of producing mobile screening equipment. Now the company is part of the Terex Group and specialises in screening, washing and recycling machines. Due to the harsh operating environment the design and manufacture of high quality, robust machines is of crucial importance to the company, which has a range of 22 main models.

The Trommel machines are designed to separate a wide range of materials including topsoil, compost, demolition waste and wood chips, while the Reclaimer machines, designed for the recycling industry, can also be used in the quarry industry for prescreening rock prior to crushing in the company's Jaw Crusher machines.

For washing applications, Finlay produces a range of machines for applications such as the washing of sand and gravel, crushed rock, quarry dust and recycled concrete.

The company carries out the design and build of these machines at its factory in Omagh, Northern Ireland and they are manufactured from a range of material including sheet metal ranging in thickness from 2mm to 25mm.

Brian Forbes, plasma programmer, said, 'All our production goes through our six Messer Griesheim plasma machines, which have bed sizes up to 12m long.' Finlay Hydrascreens decided to review its programming methods for the plasma machines, and chose SigmaNest from SigmaTEK Europe because of the power of its nesting package.

Forbes continued, 'SigmaNEST produced the best nest with the optimum material utilisation and was easier and quicker to use.' The design of the machines is carried out in Pro/ENGINEER, then DXF files of the component geometry are loaded into SigmaNEST ready for processing.

Initially, the company had created a series of fixed nests to meet demand for its products.

However, due to fluctuating order levels and customer's special requirements, this method of production resulted in shortages of some components and over supply of others.

Brian Forbes said, 'To solve the problem we moved to dynamic nesting, installing SigmaTek's SimTrans software to communicate with our MRP system.' Each week the plasma cut part requirements at Finlay Hydrascreens can be for 6000 different plasma parts, each of which can be required in various quantities, cutting up to 22000 parts per week.

'With SimTrans, we automatically get a list of parts for the week from our MRP system.

We can then, for example, nest all the 5mm thick parts for customer A, and then create another nest for customer B and so on.

The SigmaTEK software keeps track of the nested parts, only showing us the ones yet to be processed.

By the end of the week all the components are finished and we are ready for the next week's production.' Since its introduction, production has risen from 220 to 430 tonnes per week which requires approximately 600 different nests and is set to rise further in the coming months.

Forbes added, 'It would have been impossible to raise production to these levels without SimTrans.' SigmaNEST and SimTrans have also enabled the company to rationalise its sheet metal purchasing.

Fixed nests required sheet material in multiple sizes for each thickness.

The result was high stock levels and storage and handling problems in the factory.

With the introduction of dynamic nesting each sheet thickness is only ordered in one size, simplifying the nesting process and making significant savings in labour and work in progress costs.

The software helps in the identification of parts.

Each nest automatically generates part labels and sketches for each component.

The machine operator can then easily sort the parts and correctly label them ready for subsequent operations.

Forbes said, 'This is a simple and effective way of keeping track of our components.

Our next aim is to have colour coded labels so that we can easily identify the customer too.' Flexibility is provided by the ability to manually intervene in the automatic nesting process.

Parts can be added to fill up partially used sheets for maximum material utilisaton.

Finlay Hydrascreens has recently benefited from an upgrade to version 7, which gives faster nesting and easier retrieval of parts in SimTrans.

Forbes concluded, 'Nesting in SigmaNEST version 7 is at least twice as fast.

The processing of five sheets can be completed in 20 to 30 seconds.

The quality and speed of nesting which we can achieve with the software is very important to us.' * About the SigmaTEK Corporation - formed in 1992, with offices in Cincinnati, Ohio, Seattle, Washington - USA; international offices in Europe, Japan and Australia, and a worldwide distribution network, over 4000 SigmaNEST systems are now in use round the globe.

SigmaNEST software maintains its technological leadership in sheet metal nesting and cutting by a relentless commitment to research and development, providing customers with tools to maximise material utilisation and increase machine throughput while minimising programming time and effort.

Authorised training centres around the world provide after sales technical support and education to optimise productivity for users.

Highly versatile waterjet cutting offers major advantages in terms of accuracy of cut, limited material distortion and almost burr free edges, as will be demonstrated at EuroBLECH, Germany.

KMT Waterjet Systems is the leading worldwide supplier of waterjet cutting systems and at euroblech 2006 the company will be underlining the quality and high reputation of its Streamline, Active Autoline, Aqualine, Abraline and Feedline branded products. Another major attraction will be the new Streamline SL-V 200 high pressure intensifier which has a power rating of 200HP and also offers economic running costs and reliability, providing maximum waterjet cutting performance. Highly versatile waterjet cutting is acknowledged as offering customers from many different industrial sectors major advantages in terms of accuracy of cut, limited material distortion and almost burr free edges.

Whether cutting metal, plastics, ceramics, exotic and other materials, pure and abrasive waterjet cutting processes are fast, economic and accurate.

In order to achieve an operating pressure of around 4.000 bar, which is commonly required for many applications, advanced pump technology is required.

KMT Waterjet Systems provides this with the Streamline SL-V 200, which gives a powerful water flow and can operate 'around the clock' without interruption.

The major benefit is that the 200HP power rating is achieved by two intensifiers in a standard configuration.

This is a unique combination and the result is not only reduced space in the workshop, but also a minimisation of wear parts resulting in reduced operating costs and maintenance.

The flow rate of one single intensifier is 7.6 litre/min, so that the pump can supply up to 15.2 litre/min at full load.

It is also possible to switch off on intensifier when servicing is required.

A further advantage of the Streamline SL-V 200 is its patented Hard Seal Endcap Design (HSEC).

This design provides a metal-metal seal, eliminates traditional seals thereby reducing consumable costs and downtime.

The bolted end cap is also much easier to assemble at a maximum torque of just 48Nm.

For further economy and flexibility, the Soft Start feature reduces the electric current peaks to a minimum while the pump is accelerating to full speed - this provides up to 20% energy savings in power consumption when the pump is switched on.