CNC contract manufacturers who produce small and medium quantities often have limited time to determine the most economical machining strategy and optimize process parameters, unlike in large-scale production. Parts outside their current specialization typically pose significant challenges in quoting, work preparation, and manufacturing. Particularly with unfamiliar parts, companies often lack the experience needed for truly accurate calculations. Those looking to tap into new customer segments under rising cost and competitive pressure, and who wish to respond to customers faster with accurate quotes and manufacture parts profitably can reduce economic risks and complexity through Spanflug's solution for intelligent machining strategies.
“This is exactly where our Machining Intelligence comes in,” explains Dr. Markus Westermeier, CEO at Spanflug. “We now support machine shops with more than quoting and work preparation – we help them become more efficient in actual manufacturing and find new, more economical ways to machine custom parts.”
The technical basis for this is the Spanflug algorithm, which is enhanced by artificial intelligence and trained on millions of parts. The software understands each part, analyzes the optimal manufacturing process, and generates an operational plan with the required stock materials, machine tools, cutting tools, as well as times and costs.
Increasingly integrating real-world data from throughout the entire manufacturing process into Spanflug’s software is crucial to the quality of the operational plans generated and accuracy of the calculations. In addition to stock data from connected material partners, Spanflug MAKE now also utilizes tool data. The strategic partnership with tool manufacturer Ceratizit plays a key role here and now brings concrete benefits for users. “The integration of Ceratizit cutting tool data enables the software to model the manufacturing process and generate the most profitable machining strategy,” says Westermeier.
spanflug.de/en
Danobat Robotic Solutions Optimize Machining Processes
Danobat (Booth F60, Hall 11) will present robotic solutions that optimize existing processes and open new production possibilities. Earlier this year, Danobat made a bold leap into CNC precision robotics with dBOT, an innovative robot range built for operations that demand precision and dynamic performance. These robots set new industry standards by combining the flexibility of a robot with the stiffness, stability, and accuracy of a machine tool. At EMO, dBOT will showcase its capabilities with real-time machining.
Overbeck’s IRD series has long set the standard for high-precision internal and radius grinding, even on tough materials like ceramics and carbide. As manufacturing shifts toward more agile production, the IRD has been completely redesigned to meet new demands. Precise, flexible, and automation-ready, the new IRD performs internal, external, face, radius, and non-round grinding in a single setup. It integrates both radius and non-round processes within a single software platform. Designed for high-precision applications in aerospace, toolmaking and mold and die sectors, it easily handles complex geometries and delivers superior surface finishes.
The new CGX delivers versatility in a compact 13 sqm footprint: it handles OD, ID, face, and non-round grinding — among other operations — on parts up to 1,800 mm in length, 540 mm in diameter, and 500 kg in weight, making it the only grinder in its class with such a big part capacity in a compact design.
At EMO, the CGX will be equipped with an integrated MDM gauge for in- and post-process measurement, allowing real-time control of multiple diameters without interruption. Initially developed for large parts on our HG grinding machines, the MDM has proved highly effective in ensuring tight tolerances. The new MDM-100 brings that precision to smaller components (5–125 mm) and includes key improvements over previous versions. It’s an ideal solution for manufacturers working with multiple references or parts with varying diameters and continuous or interrupted surfaces — especially valuable when tight tolerances must be measured on small parts.
Historically, achieving top results in a centerless grinding relied on the operator’s knowledge. Estarta changes that paradigm by delivering expert-level results from the very first part.
Designed for fast changeovers, full ergonomics, and automatic loading in just 3.5 seconds, Estarta also includes OD and face grinding capabilities thanks to its angular configuration — ensuring burn-free results even in high-throughput environments. Its fully electric design, with no hydraulics, minimizes energy use and simplifies maintenance, making it the perfect fit for high-volume operations.
Hembrug’s Mikroturn ultra-precision hard turning lathe now integrates superfinishing and tool and workpiece measuring systems inside the machine, achieving surface finishes of Ra 0.05 µm and sub-micron profile accuracy. This all-in-one solution eliminates the need for external inspection or additional process steps. Engineered for complex threaded profiles — including gothic, round, planetary, and whitworth — the Mikroturn delivers micron-accurate parts from the very first part.
danobat.com
Siemens Expands Robotic Solutions with Sinumerik Machine Tool Robot
Siemens Sinumerik Machine Tool Robot (MTR) is a significant advance in the precision and productivity of robots that will open the door to new applications in the manufacturing industry. The Sinumerik Machine Tool Robot from Siemens is expanding the already successful Sinumerik Run MyRobot /Direct Control solution with new functions and robot types. The Sinumerik MTR enables a quantum leap in accuracy and productivity across the entire workspace. MTR is based on an intelligent control concept that gives industrial robots the characteristics of machine tools. This supports high-precision path applications, even when machining hard materials like steel, whose toughness calls for increased cutting forces and more damping.
Compared to conventional industrial robots, the Sinumerik MTR overcomes these challenges with a 200 to 300 percent increase in path accuracy and significantly higher dynamic rigidity. These characteristics make the Sinumerik MTR ideal for industries like aerospace, defense, and automotive and many other high-precision robotic applications, including post-processing of 3D-printed metal parts. In addition to improved accuracy, the new control concept brings a 20 to 40 percent productivity increase. This makes the Sinumerik MTR especially attractive for applications that don’t employ process forces, including waterjet and laser cutting. The Sinumerik MTR is controlled by Sinumerik One, the digital native CNC from Siemens. Thanks to its digital twin, it is the key element in digital transformation and helps to simulate and test workflows in a completely virtual environment.
siemens.com/global/en.html
System 3R Presents Latest Cobot Technology
The developed cobot solution C6-20L from System 3R is in line with the company’s “lights out factory” vision. This as the trend of using AMR’s (Autonomous Mobile Robots) has become more important for the industry. The C6-20L is unique from a process point of view. It utilizes sensors and ID in combination with WorkShopManager (WSM) software. The cobot also uses floor scanners so the operator can always interact with the cobot magazine and make necessary changes while the robot stops. This will ensure a safe way of making changes and a safe way of interacting with the cobot.
The cobot and all other 3R robot types/cells can be provided with the software system WorkShopManager and ID. The latest generation WSM 5.0 supports AMRs and will be presented at EMO Hannover 2025. WSM 5 allows seamless integration at the factory level, and an intuitive interface for managing complex and multi-technology workflows. Maximum flexibility is guaranteed by a simple drag-and-drop priority change by the operator on the automation control panel. Automated systems eliminate human error and allow the tracking of each workpiece, resulting in consistent output and reduced downtime.
system3r.com/en.html
Spotlight on Artificial Intelligence
Industrial manufacturing is undergoing a change for the ages. AI is finding its way into machine tools—not only changing production processes but also the maintenance of machines. AI is becoming the control center for efficient, sustainable and competitive production. In times of skills shortages and competitive pressure, it is far more than just a technological gimmick: it is becoming a survival strategy.
AI in machine tools means much more than just automation. It enables machines to learn from data, make decisions and optimize processes. Sensor technology, data analysis, machine learning and intelligent assistance systems are used for this purpose – both at the control level and in interaction with people. Learn more at EMO Hannover 2025 (emo-hannover.com)
