The machine with an old Philips control for the manufacture of single parts and very small series like machine tables, cover plates or also guide rails was getting on in years. The time for investments had come. Therefore, the management of RÖLTGEN Marking-Systems initially thought about purchasing a 3-axis machining center. After consultation with the responsible employees, however, the desire for a 5-axis machining center instead of only three axes quickly came up. However, at that time, Managing Director Frank Baehr quickly put on the "emergency brake" as, in his opinion, the range of workpieces to be produced did by no means justify such an enormous investment. “The components which we will produce on this machine have been machined in a conventional manner so far. Regarding the planned new investment, however, wishes where then expressed which would no longer be justifiable from an economic standpoint. In addition, we had the additional problem that we would have had to confront the employee responsible for that sector with new controls. Due to the risk of that employee being overstrained given his current programming know-how, the possibility of using handwheels and drilling lever seemed to us a reasonable alternative. In that way, he would have the opportunity to opt for a manual solution.“ As people in Solingen intended to achieve more flexibility with their investment and were looking for a small compact machine, the market was analyzed relatively thoroughly, information was gathered and comparisons made. Although they had already has serious thoughts about another solution, people reconsidered and decided in favor of the L version of the PICOMAX 56. The reasons for this decision were of varied nature. Comparable machines with controls and handwheels, for instance, were not equipped with tool changers.  Or electronic handwheels allowing for switching over to CNC axes at the touch of a button were not available. In comparison, the PICOMAX 56 allows for moving both axes simultaneously, gives the operator the opportunity to run a complete CNC program using an automatic tool changer and to very quickly switch to machining in a different manner using the drilling cycle and handwheels - virtually "on the fly".

Universal, flexible and full-featured
Additionally, RÖLTGEN invested in a fourth axis with one dividing head and the L version. Why the L version? Because this version provides for longer X travel up to 800 mm and a larger clamping surface of 1,400 x 480 mm compared to the standard version. Long workpieces, like e.g. shafts and guide rails, may thus be machined without re-clamping at RÖLTGEN. Due to the table size and travel, the dividing unit and tailstock may be setup so that travel is not restricted when machining shafts, for instance. This additional investment has been paying off for some time now, as the format parts sector for the pharmaceutical industry in Solingen is growing. This mainly includes the production of hot-sealing rollers for blister packaging, which may be manufactured much more efficiently using the fourth axis and the tailstock.
Another aspect is deep drilling, which poses no problem on the PICOMAX 56 with cooling through the spindle with a pressure of 40 bar.
Overall, RÖLTGEN definitely wanted a full-fledged CNC machine for the machining of different kinds of materials, such as 1.2842, 12379 as well as stainless steel and plastics and to cover the usual tolerance ranges of +/- two µm. This has succeeded. Even more: the employee about whose skills the company was worried, has developed into a full-fledged programmer who would now be able to program and operate any other CNC machine.  In this regards, Fehlmann talks about a high-precision milling machine based on a completely innovative patented operating concept. The TOP (Touch Or Program™) functions combine CNC and manual operation and allow for milling, drilling and thread-cutting work on single parts without time-consuming programming. This is why production in their own plant is ok again for Frank Baehr. „What we have is one satisfied employee who has been given the opportunity to reorient himself. On the other hand, it was also my intention to increase our throughput with the machine. And that we did.“

RÖLTGEN Marking-Systems at a glance
For 75 years, the company has been focusing on the construction and manufacture of tools for the individual marking of industrial products of all kinds. As a medium-sized family company in the third generation, RÖLTGEN has developed into one of the leading manufacturers and counts among its customers companies from the automobile, aerospace, steel and machine tool building, as well as packaging, pharmaceutical, food and cosmetics industrial sector. In addition to the comprehensive standard products, approx. 80% of the production consists of custom-made products and one-off production, like pipes, slabs, casting molds or also turbine blades.

Interesting side note
The entire production at RÖLTGEN is designed for sustainability, the sensible treatment of the environment and natural resources.  An efficient cleaning system of the electroplating waste waters, a rain water processing and usage plant, as well as a photovoltaic installation have already been used for years.

By the way ...
How efficiently the PICOMAX 56 L TOP may be used in small-series production becomes quite clear when having a look at the equipment features: Heidenhain Control TNC 620, a liquid-cooled and high-torque motor spindle for the universal milling up to speeds of 12'000 rpm as well as Z/S interpolated thread cutting, 3D milling, boring. etc.

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