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Makino Europe’s Customer Magazine

Precisely!ww

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02|2015

ACATEC AERONAUTICS Flying higher in 5-axis machining

HBC STEEL GUARANTEED MACHINING

Ready for take-off – and landing

FUSTELLIFICIO TOSCANO

Artisan excellence for haute couture

A safe landing in Makino Europeʼsunique aerospace centre

Makino Europe’s Customer MagazinePrecisely! 02|20152

With the European machine tools market off ering favourable perspectives for the next three years, and aerospace in particular booming, Makino Europe is continuing the invest-ments to promote premium-quality production technologies. in Kirchheim unter Teck (near stuttgart) the capacity of the technology centre will very soon be expanded to accommodate Makino’s largest showroom in Europe. Best-in-class technol-ogies in aerospace, die & mould and parts manufacturing will be demonstrated on more than 2000 m2. The technologies on show will range from high-performance machining of titanium and aluminium structural parts to micro-technology and mirror-surface applications. The very fi rst shows in the expanded facility, the Aerospace Forum 2015 and Die & Mould Forum 2015, will be held on 24-26 november this year. i would like to take this opportunity to invite you to an inspiring mix of lectures, customer testimonials and live demonstrations with ample opportunities to network with users in your own and other fi elds of expertise. on 22-25 september this year, Makino will also host an exclu-sive event at its italian subsidiary in Cavenago di Brianza (near Milan). This technology show will include an Automotive Forum and a Die & Mould Forum, and see the launch of a number of new products, including the a40 horizontal machin-ing centre designed for reducing cost per part in aluminium die-cast applications for automotive and industrial compo-nents, as well as the EDnC6 sinker EDM with a new Hyper i controller. The event will focus on two specifi c subjects: reducing the cost per part in medium- to large-volume parts production applications and minimising manual re-working in plastic mould making. i would like to invite you to join us at what will surely prove to be a most valuable event.

in this edition of Precisely, we feature customer success stories from spain, italy and the Czech republic. ACATEC Aeronautics, one of spain’s leading Tier 2 aeronautical suppliers, sees 5-axis machining as the key factor in producing structural parts for aircraft and believes Makino builds the best CnC machines for working titanium (pages 4-6). Fustellifi cio Toscano is most probably unique among Makino’s customers in that it supplies its products to top fashion brands such as Prada, Gucci and Yves saint Laurent (pages 11-13). Last but not least, we portray HBC steel Guaranteed Machin-ing, a customer from the Czech city of olomouc (pages 8-10). in only six years HBC has built up a thriving job-order parts production business and recently purchased its fi rst Makino MAG1 to be installed in Central Europe as an investment in the company’s aerospace future.

Enjoy the reading and remember to save the dates of our technology shows in Cavenago and Kirchheim!

Yours sincerely,

P. Anders ingemarssonPresident & CEo Makino Europe

Dear Reader,

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4 ACATEC AERONAUTICS Flying higher in 5-axis machining 8 HBC STEEL GUARANTEED MACHINING ready for take-off – and landing 11 FUSTELLIFICIO TOSCANO Artisan excellence for haute couture 14 Makino Europe News

Contents

We kindly invite you to join us at the following events:

International Automotive Forum, Cavenago di Brianza, italy 22 - 23 september 2015 Die & Mould Forum, Cavenago di Brianza, italy 24 - 25 september 2015 Fakuma, Friedrichshafen, Germany 13 - 17 october 2015Die & Mould Symposium at the Consulate General of Japan,Moscow, russia 28 october 2015 AIRTEC, Frankfurt/Main, Germany 3 - 5 november 2015metalmadrid, Madrid, spain 4 - 5 november 2015 FMB, Bielefeld, Germany 4 - 6 november 2015Aeromart, Toulouse, France 4 - 6 november 2015 Die & Mould Forum, Kirchheim unter Teck, Germany 24 - 26 november 2015International Aerospace Forum, Kirchheim unter Teck, Germany 24 - 26 november 2015TechniShow, utrecht, netherlands 15 - 18 March 2016

For detailed information and registration, please go to www.makino.eu. We are looking forward to your visit!

Events2015/2016


Flying higher in 5-axis machining ACATEC Aeronautics is not just one of Spain’s leading Tier 2 aeronautical suppliers but

also in the vanguard of European aeronautical manufacturing. Up to four years ago,

ACATEC had been unwaveringly loyal to other manufacturers of CNC machines.

But when a highly versatile solution was required to machine titanium, ACATEC went

for its first horizontal machining centre from Makino. This a92-5XR performed so

well that, two years ago, ACATEC decided to invest in a Makino A100ε-5XR and is

highly satisfied with the 5-axis machining performance of both Makino machines.

ACATEC AEronAuTiCs

Flying higher in 5-axis machining

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Precision machining at ACATEC

Top OEM and Tier 1 customersACATEC’s clientele includes some of the top names in the oEM and Tier 1 aeronautical supplier industry. The structural parts, sub-units and assemblies ACATEC manufactures from aluminium, titanium, stainless steel, inconel® and carbon fi bre are built into the Airbus A320, A330, A350 and A380, the Embraer 145, 170, 190 and KC-390, the Fokker nH90 and the sikorsky s-92. This rapidly expanding family business operates from two sites in the Greater Madrid region, Arganda del rey and Getafe.

Expanding family businessACATEC’s expansion is refl ected in a fast-growing workforce – currently 150 employees – and a rising annual turnover, which reached €12 million in 2014. Broadly based aeronautical expertise based on over 20 years of experience in this sector enables ACATEC to off er its customers tailored solutions for individual parts, sub-units and entire assemblies (e.g. the A-320 HTP). ACATEC’s experience in manufacturing aeronautical parts has enabled the company to optimise the diff erent phases of pro-duction to create a smoothly integrated and highly productive production process. The manufacturing portfolio is rounded off by a variety of surface treat-ments for aluminium, titanium and stainless steel parts, e.g. chemical conversion and chromic, sulphuric or tartaric anodising, as well as painting and sealant applications under nADCAP/Airbus certifi cation.

Precision machining at ACATEC

Top OEM and Tier 1 customersACATEC’s clientele includes some of the top names in the oEM and Tier 1 aeronautical supplier industry. The structural parts, sub-units and assemblies ACATEC manufactures from aluminium,

Fokker nH90 and the sikorsky s-92. This rapidly expanding family business operates from two sites in the Greater Madrid region, Arganda del

Expanding family businessACATEC’s expansion is refl ected in a fast-growing workforce – currently 150 employees – and a rising annual turnover, which reached €12 million in 2014. Broadly based aeronautical expertise based on over 20 years of experience in this sector enables ACATEC to off er its customers tailored solutions for individual parts, sub-units and entire assemblies (e.g. the A-320 HTP). ACATEC’s experience in manufacturing aeronautical parts has enabled the company to optimise the diff erent phases of pro-duction to create a smoothly integrated and highly productive production process. The manufacturing portfolio is rounded off by a variety of surface treat-ments for aluminium, titanium and stainless steel parts, e.g. chemical conversion and chromic, sulphuric or tartaric anodising, as well as painting and sealant applications under nADCAP/Airbus certifi cation. One of numerous aeronautical parts ACATEC makes


ACATEC AEronAuTiCs

Dedicated to quality and precisionThis family fi rm’s success is due, not least, to a rigorous dedication to qual-ity and precision in all its operations in order to meet the aviation industry’s strict technological and productivity demands. But this in turn is only possible thanks to a highly motivated workforce led by Doroteo Gonzalez, one of ACATEC’s founders and current General Manager, Plant Manager Jesús Luis Esteban, Purchasing Manager raúl Liébana, Production Manager Manuel Muñoz, and all the ACATEC team.

“Makino best for titanium”There were two reasons why Doroteo Gonzalez considered buying a Makino machining centre: fi rstly, the produc-tivity gains achievable through reliable, high-performance 5-axis machining of titanium and aluminium components; and secondly, the long-lasting business relationship with ricardo del Villar, Country Manager, Makino iberia. “5-axis machining was a key factor and we think Makino builds the best machines for working titanium,” raúl Liébana explains. The 5-axis Makino a92-5Xr horizontal machining centre ACATEC bought four years ago is deployed to produce structural parts, such as those required for Airbus tail fl aps.

ACATEC was so satisfi ed with the performance of the a92-5Xr that they decided to invest in another 5-axis horizontal machining centre from Makino in 2013. This A100ε-5Xr fea-tures a high-torque 1,009 nm spindle for machining tough-to-cut titanium. “Here, too, we felt Makino off ered us the best option for machining a specifi c titanium part,” raúl Liébana says. This second 5-axis horizontal machining centre has also performed well overthe past two years, as Manuel Muñoz relates: “We particularly like its precision and good behaviour and are very satisfi ed with the quality of the output and the machine’s reliability.”

Both Makino machines are playing a key role in fulfi lling ACATEC’s own high standards of quality and precision, and meeting the strict requirements of demanding customers in the aero-nautical industry.

Jesús Luis Esteban, Raúl Liébana and Manuel Muñoz (f. l. to r.)

“We think Makino builds the

best machines forworking titanium.”

Technology Days 2015

More than an exhibition!

International Automotive Forum22 - 23 septemberCavenago di Brianza, italy

Die & Mould Forum24 - 25 september, Cavenago di Brianza, italy24 - 26 november, Kirchheim unter Teck, Germany

International Aerospace Forum24 - 26 novemberKirchheim unter Teck, GermanyGermany


Ready for take-off –

and landing

HBC sTEEL GuArAnTEED MACHininG

The fi rst Makino MAG1 in Central Europe has been installed

at HBC Steel Guaranteed Machining, a young but dynamically

expanding company located in the Czech city of Olomouc.

In only six years HBC Steel’s visionary owner, Pavel Hemžský,

has built up a thriving job-order parts production business.

Recently, he invested in a MAG1 to equip his company for

manufacturing large aerospace parts.

Airbus landing gear component

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Strong in parts production Established in 2009, HBC steel began by producing spare parts for pumps. Pavel Hemžský: “Although i had set up my own sales company back in 1997, it was always my vision to produce parts – and that’s why i founded HBC steel.” six years on, HBC steel employs 35 people and has an annual turnover of Kč 45 million (€ 1.66 million). now, pumps account for only 5% of turnover and parts production for 95%. “We use the world’s best CnC machines to manufacture precise and technologically demanding parts for the chemical and petrochemical industry, the automotive industry and the aerospace industry,” Pavel points out. HBC steel’s product portfolio includes parts for mechanical seals, flanges and rotary joints for chemical/petrochemical customers such as John Crane and specac; small-series production (e.g. tow bars, punching and forming tools for automotive chassis and forging dies) for automotive customers such as the Volkswagen Group (Škoda) and Benteler; prototype parts for motorbikes and Polaris quads; and aerospace structural parts and landing gear components for the Airbus A350 and A320.

“Investment in the future”With the aviation industry transporting ever more passen-gers and freight, the demand for new aircraft is unabated, particularly as new developments such as the Airbus 320 neo promise significant fuel savings. Petr Pavka, Makino’s Head of Consulting & sales, Central Europe (southeast), outlines another important trend: “Although Airbus is consolidating its tier 1 and tier 2 suppliers, the number of sub-contractors is increasing accordingly to meet the growing demand for structural parts. it is crucial that by 2016, suppliers have the necessary capacity to meet this demand.” Pavel Hemžský has recognised this huge potential in the market for aerospace suppliers and responded by purchasing a Makino MAG1, the 5-axis horizontal machining centre specifically designed for manufacturing structural parts of up to 1.5 metres in length. “For me it’s an investment in the future because aerospace is booming and Makino’s MAG 1 is the best reference for structural parts,” Pavel Hemžský explains. “it underlines the reputation we already have for accuracy and quality in parts production, and equips us in the best possible way for this growing market.”


Networking matters: Pavel Hemžský (l.) and Petr Pavka

Makino’s networking role“Aerospace is like the automotive industry,” Petr Pavka points out. “it’s all about trusting your suppliers. The key factor is to build up trusting relationships, and our job at Makino is networking – smoothing the way to trusting relationships by bringing quality companies together.” in the case of HBC steel, Makino was instrumental in establishing a fruitful relationship between HBC steel and the largest aerospace manufacturer in the Czech republic. one outcome was the purchase of the MAG1 with a 33,000 rpm, 120 kW spindle. The machine was delivered to HBC steel in January 2015 and “installation went very well”, as Pavel Hemžský confi rms. But this machine was not the only signifi cant investment Pavel has made in his company’s aerospace future.

Paving the wayFor the fi rst fi ve years after HBC steel was established, the company was housed in a small 300 m2 building. But its rapid expansion necessitated a move – not least to accommodate the MAG1 and meet the requirements placed on aerospace suppliers. “in october 2014 we moved to new premises with 3,000 m2 of space for production and 200 m2 for offi ces,” Pavel Hemžský explains. “We need approved premises, facilities and equipment to get a clean audit from aerospace tier 1 and tier 2 suppliers. Those conditions are now met, and with the MAG 1 on board we’re ready for take-off !” The fi rst MAG 1 to be installed in Central Europe means HBC steel is perfectly placed to meet the growing demand for aerospace parts.

“Our job at Makino is networking.”

HBC sTEEL GuArAnTEED MACHininG

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An unpretentious craft workshop near Florence: Fustellifi cio Toscano.

Their clientele: top fashion brands like Prada, Gucci, TOD’S, Chanel

and Yves Saint Laurent. Their niche: making the hard steel dies used

to cut intricately shaped leather for haute couture shoes, bags and

clothes. The secret of their success: craft skills, a passion for precision

and state-of-the-art cutting technology.

FusTELLiFiCio TosCAno

Dies for haute couture leather goods

Ugo Naldini (r.) and his son Leonardo Naldini talking to

Makino's Alessandro Senzapaura

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Artisan excellence for haute couture


Florence, the tourist magnet at the heart of Tuscany, is also the capital of Tuscany’s world-famous leather industry. Exclusive leather goods from the world’s best-known brands sell at premium prices – whether it’s an iPhone cover or an Yves saint Laurent bag. Yet only a few industry insiders realise that the first steps in manufacturing many of these haute couture shoes, bags and clothes are taken in an inconspicuous craft workshop in the small town of Figline Valdarno, some 35 km southeast of Florence.

An artisan workshopThe first impression on entering Fustellificio Toscano’s unassuming premises is of a small artisan business: simple surroundings, no big machines, craftsmen working with cardboard and metal. Yet appearances can be deceptive. Fustellificio Toscano, a family business founded by ugo naldini in 1978, manufactures the precision cutting dies required for haute couture leather goods. its clients include all the big names in fashion, and a few of the ‘hidden champions’ as well. As ugo naldini points out, “The best leather goods actually come from an artisan brand in Florence: il Bisonte.”

ugo (60) and his son Leonardo (34) run the family business with its 22 employees. 60% of the cutting dies Fustellificio Toscano makes are for shoes and boots, 35% for bags, and 5% for various kinds of clothes. What they all have in common is their destination: the haute couture industry, a specialist niche that probably needs some explaining to most Precisely readers.

A precision production processFashion shoes, boots and bags start life as a designer drawing. At Fustellificio Toscano specialist software turns this drawing into a 3D model, and in the case of shoes to all the required sizes as well. These files are fed into a machine that cuts 2D cardboard patterns of each and every part. These cardboard patterns are then scanned into a machine that produces the steel strips used to form the dies. The next stage is pure craftsmanship. skilled workers turn the long strips of 48-50 HrC steel into the precise shape of the cutting die. The die is first held together with sticky tape before being welded into position. The final stages – finishing and quality control – are also predominantly manual operations. The cutting dies for haute couture bags often feature small pins that will punch tiny holes into the leather of a fashion bag during the manufacturing process. At Fustellificio Toscano these pins are inserted by hand into holes predrilled in the metal cutting dies. it was to drill such tiny holes in the cutting dies that Fustellificio Toscano invested in a Makino F5 vertical machining centre in May 2014.

5 %

60 %35%

FusTELLiFiCio TosCAno

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A reliable machine in unmanned cutting operations“We bought the F5 because we needed a machine we could trust for high-precision quality and totally reliable unmanned operations over long periods,” explains Leonardo naldini. Machining times vary between 2 and 20 hours. “since the fashion industry is now demanding more and more complex cutting dies, another of our requirements was that the machine is capable of running sophisticated cutting programs.” ugo and Leonardo naldini were not just looking for a strong and reliable vertical machining centre, but also one that can work with tiny tools “without breaking them after just fi ve hours,” as Leonardo adds. “We are very happy with the F5’s perfor-mance,” Leonardo says with a smile.

A name to rememberHoused in a separate room of the Fustellifi cio Toscano work-shop, the F5 is not immediately visible to the fi rst-time visitor. Yet this Makino machine plays a key role in maintaining the highest standards of craftsmanship and precision quality that have made Fustellifi cio Toscano a key player in the haute couture leather goods industry. so next time you buy some leather shoes from Churchill (a Prada brand) or a fashion bag from ToD’s, remember that the manufacturing story began at a little-known artisan workshop where craft skills, a passion for precision and a Makino F5 make stylish haute couture products possible.

A skilled worker creates the precise shape of the cutting die from a long steel strip;

the die is fi rst held together with sticky tape and then welded into position.


newsMakino Europe

Accurer of san Fernando de Hernares near Madrid purchased an a61nx-5E in 2014 to machine aerospace parts.

Sevilla Control, an aerospace supplier based in seville, invested in an a61nx in 2014.

The aerospace supplier C.A.D.A. Madrid purchased an a61nx in 2014.

Stöfele Automotive, a prototype and series parts’ producer based in Laupheim, Germany, bought an a61nx in 2015.

PRAE-AERO of schwanewede-Brundorf, Germany, invested in a U3 in 2015.

IKO Isidor Kurz Werkzeug- und Formenbau, a die & mould maker from Haigerloch, Germany, purchased an a61nx in 2015.

24h ServiceEven after machine installation Makino remains your reliable, long-term partner.

Makino has branches in

17countries

around the world, 9 of them in Europe. Makino has further expanded and opened up a new branch in Europe: Makino Poland in Piaseczno.

purchased an a61nx in 2015.

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in 2015, GLN moldes, a high-tech mould maker from Maceira, Portugal, has acquired a D500, V33i-5XB Graphite, iQ300 and two EDAF3s with an Erowa robot.

Palbit S.A. of Branca Alb.-a-Velha, Portugal, purchased an iQ300 to make tungsten carbide tools.

Madelmold, a die & mould maker based in Madrid, invested in a D300 in 2015.

Combi Tools Aps, a precision die-casting mould maker based in Jordrup, Denmark, bought a U6 in 2014, a D300 and a F5 in 2015.20

00Makino a51nx and a61nx:optional direct drive motor B-axis reduces table indexing times by

opening of Technology Centre in Kirchheim unter Teck, Germany.

if you would like to fi nd out more about the Makino portfolio, a specifi c product or anything else mentioned in this magazine, or if you have any other questions or enquiries, please get in touch with:

Andreas Walbert, [email protected]

Publisher: MAKino Europe GmbHEssener Bogen 5, 22419 Hamburg, Germany+49 (40) 29809-0Director of publication: P. Anders ingemarssonPhotos: Makino

30%

Aciturri, a tier 1 aerospace supplier based in Madrid, invested in a MAG3 in 2015.

Makino Europe GmbHEssener Bogen 522419 Hamburg, Germany+49 (40) 29809-0

4th Dobrininsky Pereulok 8offi ce C13-02119049 Moscow, russia+7 (495) 98982-20

Makino GmbHEssener Bogen 522419 Hamburg, Germany+49 (40) 2980 9-0

Kruichling 1873230 Kirchheim unter Teck, Germany+49 (7021) 503-0

Makino s.r.o.Tuhovská 31 83106 Bratislava, slovakia+421 (2) 49612-100

Ve svahu 482/5147 00 Prague 4, Czech republic+421 (2) 49612-100

Makino Sp. z o.o.ul. nowa 10, stara iwiczna05-500 Piaseczno, Poland+48 (22) 3781 950

Makino France S.A.S.Bat. ronsard Hall A Paris nord 222 Avenue des nations, Cs 4504595912 roissy Charles De Gaulle Cedex, France+33 (1) 787843-20

Makino Italia S.r.l.strada Privata delle orobie 520873 Cavenago di Brianza (MB), italy+39 (02) 959482-90

Makino Iberia S.L.U.C/Agricultura, 16 – 18, 2º 4ª08320 El Masnou, Barcelona, spain+34 (93) 5559515

www.makino.eu

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