Category: Blog

Five-axis CNC milling technology is available in two main configurations: vertical machining centers (VMCs) and horizontal machining centers (HMCs). Choosing the right one can significantly influence precision, efficiency, and overall production costs. Below is a breakdown of how these two setups differ in operation, advantages, and limitations.

Vertical 5-Axis Machining

In a vertical machining setup, the spindle approaches the workpiece from above, moving along the z-axis. Rotational movement is typically provided by trunnion-style tables, which allow two additional axes of flexibility.

Advantages of VMCs:

• Compact tool setups: Because vertical machines often feature smaller spindles, operators can use shorter tools, which improves rigidity, extends tool life, and enhances surface quality.
• Clear visibility: The open structure of a VMC allows operators to directly monitor machining progress, making troubleshooting easier.
• Ease of use: Since vertical 5-axis systems are widely used, operators usually adapt quickly, reducing training time.
• Lower upfront cost: VMCs are typically more affordable than horizontal units, lowering the financial barrier for workshops.
• Space efficiency: Their relatively small footprint makes them easier to integrate into existing production floors.
• High precision: Ideal for jobs requiring intricate details, such as tool and die manufacturing.

Challenges with VMCs:

• Setup interruptions: Parts cannot usually be swapped while machining is in progress, which may slow down throughput unless automation is added.
• Chip management issues: Material chips often accumulate around the workpiece, potentially affecting tool wear and finish quality.

Horizontal 5-Axis Machining

With horizontal machines, the spindle runs parallel to the ground and moves along the y- and z-axes. These machines are often chosen for large-scale or heavy-duty milling where material removal rates are high.

Advantages of HMCs:

• Efficient chip evacuation: Gravity naturally assists in clearing chips and coolant, which improves part quality and reduces tool wear.
• Higher productivity: Thanks to rotating tables, new parts can be loaded while others are being machined, minimizing downtime.
• Operational flexibility: Some HMCs allow entire milling heads to be swapped, enabling multiple processes within one setup.
• Reduced labor input: Continuous operation with minimal idle time helps lower staffing costs over the long run.

Challenges with HMCs:

• Space requirements: HMCs occupy more floor area, though this often comes with increased production capability.
• Higher investment: The robust construction and larger design make them considerably more expensive than VMCs.

Which One to Choose?

The decision largely depends on the type of work being done. Vertical 5-axis machines are well-suited for smaller, highly detailed parts and offer a cost-effective entry point for precision machining. Horizontal systems, on the other hand, excel at large, heavy parts and continuous high-volume runs, making them better suited for industrial-scale operations.

Both machine types can be enhanced with automation solutions, enabling manufacturers to maximize spindle time and efficiency regardless of configuration.

In modern precision manufacturing, efficiency depends not only on the CNC machines themselves but also on the supporting technologies that keep them accurate and versatile. Among these, rotary tables have emerged as a critical—yet often overlooked—component. Their ability to rotate, index, and precisely position workpieces enables advanced 4-axis and 5-axis operations, making them indispensable across industries such as aerospace, motorsport, medical device production, and toolmaking.

Why Rotary Tables Matter

If a rotary table fails, an entire machining center can grind to a halt. Original equipment manufacturer (OEM) repairs are often expensive and slow, leaving manufacturers with the challenge of either facing costly downtime or seeking third-party expertise. For UK workshops, reliable local repair, retrofit, and upgrade services have become a lifeline—especially for small and medium-sized enterprises working under capital constraints.

The CNCROTARY.COM Approach

One company stepping into this gap is CNCROTARY.COM, which focuses exclusively on rotary systems. Its services include repairing, upgrading, and building custom rotary units to suit specific production needs. The firm works with a wide portfolio of brands—Fibro, Peiseler, Haas, Nikken, Kessler, Cytec, Tsudakoma, Kitagawa, and many more—ensuring customers aren’t locked into costly OEM-only solutions.

For example, a recent refurbishment project documented by the company involved salvaging a high-value rotary system initially thought to be beyond repair. After a comprehensive rebuild—including mechanical overhauls, recalibration, new seals and bearings—the unit was restored to full functionality, providing the client with a cost-effective alternative to outright replacement.

Tailored Engineering for Competitive Advantage

The benefits of such services extend beyond cost savings. Many manufacturers are now prioritizing asset life extension, sustainability, and operational flexibility. Custom-built rotary tables, whether designed for multi-spindle setups, compact footprints, or non-standard bores, allow businesses to adapt equipment to evolving production demands without major reinvestment.

CNCROTARY.COM also supplies brand-new rotary tables—both standard and bespoke—engineered in close collaboration with clients. By matching specifications to the exact requirements of a production line, the company helps ensure seamless integration and minimal downtime.

Looking Ahead

With more than 40 years of engineering experience, CNCROTARY.COM positions itself as a bridge between standard off-the-shelf parts and fully tailored motion-control solutions. As CNC technology continues to advance and AI-driven automation expands into workshops, rotary integration will likely play an even bigger role in maintaining precision and uptime.

The question for UK manufacturers now is not just how to keep machines running, but how to do so strategically—maximizing productivity through smarter servicing, targeted retrofits, and partnerships with specialists who understand that every minute of downtime has a cost.

Italy’s machine tool, robotics, and automation sector is cautiously entering 2025 with expectations of mild growth after enduring a significant downturn in the previous year. The domestic market experienced a steep contraction in 2024, yet the industry managed to hold its place on the global stage—retaining its position as the fifth-largest producer and fourth-largest exporter worldwide, based on figures from industry body Ucimu-Sistemi Per Produrre.

In 2024, total production within the sector declined sharply by 16.9%, reaching €6.3 billion. Domestic demand plunged, resulting in a nearly 40% drop in local deliveries. At the same time, machinery imports shrank by 31.8%, settling at €1.65 billion. This combination of weakening internal demand and reduced import activity reflected broader market uncertainty and cautious investment behavior.

Amid these challenges, foreign sales became a rare source of momentum. Exports increased modestly by 1.2%, hitting a new high of €4.27 billion. Positive performances were noted in markets such as the United States (up 10.9%), Germany (1.6% growth), and India (a notable 58.3% rise). However, demand decreased in other key destinations, including China and France, which saw double-digit contractions. Conversely, Spain and Sweden registered strong increases, with Swedish demand surging over 70%.

Looking to 2025, Ucimu’s research division projects a mild rebound across several metrics:

• Production is forecasted to grow by 2.6%, reaching approximately €6.49 billion
• Exports are set to rise by 1%, potentially establishing a new record at €4.31 billion
• Domestic shipments may increase by 5.9%
• Imports are expected to recover slightly, with a 4.9% gain

Despite the slightly improved outlook, significant risks remain. The broader geopolitical climate—marked by trade disputes, conflicts, and the threat of protectionism—continues to cloud projections. Ucimu underscores the importance of adopting a cautious and adaptive approach amid such volatility.

To support sustainable recovery, industry leaders are urging ongoing investment in technological advancement, digital transformation, and workforce training. Initiatives such as Transition 4.0 and 5.0 are seen as critical levers for driving competitiveness. Italy’s industrial base must remain closely aligned with evolving European manufacturing ecosystems, especially as countries like Germany pursue major reindustrialisation agendas.

One prominent strategic effort is the UCIMU Academy, which focuses on bridging the skills gap through stronger collaboration between businesses, technical schools, and universities. The program aims to equip future professionals with the knowledge and experience needed to navigate increasingly automated and digitized production environments.

Additionally, sector leaders are monitoring global shifts such as the electrification of the automotive industry and evolving trade regulations, particularly those that could influence access to U.S. markets. While direct impacts from tariffs may currently be limited, indirect consequences through multinational supply chains remain a concern.

As Italy’s manufacturing sector recalibrates after a turbulent year, stakeholders are calling for unified efforts to reinforce resilience and secure long-term growth.

OTT-JAKOB Spanntechnik, a German leader in tool clamping technology, has expanded its portfolio with the introduction of the Power-Check Micro—a compact device designed to assess clamping force in small-scale spindle interfaces. This newly developed tool caters to the needs of high-precision industries where space is limited and accuracy is critical.

Tailored for miniature spindles such as HSK E15, E16, and E20, the Power-Check Micro is intended for use in applications like dental technology, fine jewelry production, micro-component manufacturing, and sectors including aerospace and medical instrumentation. These industries depend heavily on stable, repeatable clamping performance due to the delicate nature of their machining tasks.

Distributed in the UK and Ireland through Gewefa UK, the Power-Check Micro is engineered to meet rising demands in miniature manufacturing for consistent monitoring and predictive maintenance. Unlike traditional measuring systems designed for large spindle formats like HSK 160, SK, or BT, this device fits seamlessly into smaller machine environments, thanks to its compact design—measuring just 48.8 x 43 x 41.5 mm and weighing approximately 200 grams.

The Power-Check Micro is battery-operated, eliminating the need for external power sources. Two replaceable lithium cells provide up to 1,000 hours of operation. Its wireless communication system transmits real-time data at a frequency of 2.4 GHz, with updates delivered once per second to a receiver. Integration is flexible, with USB and IO-Link modules available to support various digital workflows.

One of its standout features is the precision adjustment ring, which allows users to simulate deviations in tool holder size by increments of 0.05 mm, up to a ±0.2 mm range. This functionality enables more accurate replication of real-world tolerance variations—something rarely possible with static, nominal-only measurements.

The device supports interchangeable threaded adapters to suit different HSK interface sizes and is compatible with a broad range of tool clamping systems. Like its larger siblings in the Power-Check lineup, it measures axial drawbar force—ensuring that the retention mechanism holds the tool securely. A drop in clamping force may signal potential problems such as tool slippage, poor surface finish, or even catastrophic failure—risks that are unacceptable in high-precision machining.

Note that the Power-Check Micro is intended for manual insertion only and should not be used during automatic tool changes or while the spindle is running.

Users can purchase the device individually or as part of a comprehensive kit that includes software, a USB receiver, batteries, and a protective case. Routine calibration and scheduled testing are advised to keep measurements consistent and reliable.

With the Power-Check Micro, OTT-JAKOB continues to deliver advanced, user-friendly tools that help manufacturers uphold tight tolerances and maintain high standards—even at miniature scale.

This week marked a significant moment in industrial manufacturing as industry experts visited Picanol’s state-of-the-art facility in Belgium. The weaving machine manufacturer, renowned for its global leadership in textile technology, recently celebrated an extraordinary achievement – the sale of its 400,000th weaving machine worldwide, cementing its position as an industry pioneer.

Revolutionizing Textile Manufacturing Through Innovation

Picanol’s success stems from its relentless pursuit of manufacturing excellence. The company has implemented groundbreaking production strategies that significantly reduce assembly times while maintaining exceptional quality standards. A key component of this strategy involves their strategic partnership with IBARMIA, a leader in precision machining technology, and their local partner Geroud.

Next-Generation Manufacturing Solutions

The centerpiece of Picanol’s technological advancement is a revolutionary IBARMIA machining system featuring:

• An innovative moving column design
• An expansive 8-meter X-axis capacity
• Dual-spindle configuration
• Integrated robotic automation

This comprehensive manufacturing solution represents a quantum leap in production efficiency. The system’s intelligent design enables simultaneous machining operations, dramatically increasing output while maintaining Picanol’s renowned precision standards. The automation components significantly reduce manual intervention, minimizing production interruptions and enhancing overall equipment effectiveness.

Engineering the Future of Textile Manufacturing

Picanol’s investment in this advanced manufacturing technology demonstrates their commitment to maintaining industry leadership. The IBARMIA integration provides:

1. Enhanced production capacity to meet global demand
2. Improved machining accuracy for superior product quality
3. Optimized workflow efficiency through intelligent automation

This strategic equipment selection reflects Picanol’s forward-thinking approach to manufacturing. By combining precision engineering with smart automation, the company continues to set new benchmarks in weaving machine production, ensuring they can deliver their industry-leading solutions to customers worldwide with unmatched efficiency and reliability.

The successful implementation of this advanced manufacturing system underscores Picanol’s dedication to technological innovation as they continue to shape the future of textile production on a global scale.

DMG MORI has introduced two new advanced machining centres—the DMX 60 U and DMX 80 U—designed to elevate five-sided machining performance across various manufacturing sectors. Built on the trusted architecture of the company’s DMV vertical 3-axis machines, these upgraded models promise exceptional precision, productivity, and operational efficiency.

Represented in the UK by DMG Mori UK Ltd (Coventry), the new DMX U line brings a smart solution for manufacturers working with mid-sized components. The DMX 60 U handles up to 300 kg, while the DMX 80 U accommodates up to 350 kg, both offering ample workspaces: 600 x 600 x 510 mm and 800 x 600 x 510 mm, respectively.

Central to the machines’ stability is their rigid monoblock bed design, reinforced by heavy cast iron components and broad roller guideways. This structural approach delivers up to 50% greater static stiffness compared to earlier models, allowing for stable performance under dynamic machining conditions. With rapid traverse speeds reaching 42 m/min and enhanced B- and C-axis rotation rates (up to 10 rpm), users can expect a significant gain in cycle time efficiency.

Precision is further enhanced through features like multi-sensor thermal compensation and direct-drive systems. Linear encoders on the X and Y axes help maintain exact positioning over time, making the machines ideal for tight-tolerance components.

Standard spindle configurations include the 12,000 rpm inlineMASTER, though users can opt for higher-performance options such as the SpeedMASTER series, offering speeds of up to 20,000 rpm or high torque of 200 Nm. Tool magazine capacities are scalable from 30 to 120 tools, and all setups utilize the BIG PLUS face-and-taper interface for improved rigidity and machining accuracy.

The DMX U series also supports integrated processes such as in-machine grinding, minimizing the need for separate operations and reducing overall setup time. For full automation, the machines are compatible with DMG MORI’s Robo2Go Milling, MATRIS Light, and PH Cell systems.

Users can choose between Siemens Sinumerik ONE or Heidenhain TNC7 CNC platforms, both with CELOS X—DMG MORI’s digital interface for intuitive machine operation and seamless workflow integration. For eco-conscious operations, the built-in GreenMode feature offers energy savings of up to 10%.

By combining compact design, high flexibility, and cutting-edge digital control, the DMX 60 U and DMX 80 U stand as key additions to DMG MORI’s portfolio, catering to modern production demands with precision and sustainability at the forefront.

In a major strategic move, GE Aerospace is set to invest more than €78 million into enhancing its manufacturing footprint across Europe in 2025. This initiative reflects the company’s drive to support growing demand in both the commercial aviation and defence sectors through technological advancement and production scale-up.

At the heart of the plan is a focus on next-generation aerospace components, utilizing advanced materials and smart manufacturing solutions. GE aims to deliver engines that excel in performance, endurance, and fuel efficiency—meeting the evolving standards of modern aviation. The expansion will also open over 500 new positions across Europe, contributing to job growth and regional economic development.

Riccardo Procacci, who leads GE Aerospace’s Propulsion and Additive Technologies division, emphasized the strategic significance of the effort:
“With this investment, we’re not only responding to industry needs but also strengthening our role as a key contributor to European aerospace innovation and local economies.”

Key Areas of Development

A significant share of the funding will be used to expand testing infrastructure and install AI-driven inspection systems, alongside acquiring state-of-the-art manufacturing equipment. These enhancements are designed to increase production volumes for both civil and military aircraft components, including those for helicopters and fighter jets.

The investment will be spread across facilities in five European nations, each playing a unique role in GE Aerospace’s regional supply chain:

• Italy will receive the largest allocation (€55.6 million), which will go toward upgrading engine test cells, implementing modern inspection technologies, and modernising multiple manufacturing sites.
• Poland is set to benefit from €11.6 million aimed at expanding machine capacity and improving utilities and infrastructure for engine production, especially for commercial aircraft and rotorcraft.
• In the Czech Republic, €5.4 million will be used to acquire new machinery and tools for producing parts for turboprop engines.
• The United Kingdom will see a €3.3 million injection to increase its output of aerospace components and enhance its servicing of propeller systems.
• Romania will receive €2.3 million for the installation of precision metalworking machines and facility upgrades.

This new commitment builds on GE Aerospace’s prior investments in the region, which included €64 million allocated in 2024 for European manufacturing growth and an additional €122 million for maintenance, repair, and overhaul (MRO) and component servicing operations.

Investing in Talent and Innovation

Beyond infrastructure, GE Aerospace continues to cultivate technical talent through apprenticeships in countries like Poland and the UK. The company also supports STEM education initiatives such as Poland’s Next Engineers programme and Italy’s ITS Academy in Torino—nurturing future innovators and engineers.

With this latest financial commitment, GE Aerospace reinforces its position as a cornerstone of European aviation and its dedication to developing cutting-edge technologies and resilient supply chains.