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Two identical fiber lasers for rapid series part production including beveling

Sought and found: Two state-of-the-art 3D laser cutting systems

For the rapid production of high-precision series parts, steel specialist Ferro Service Sp z o.o invested in two fiber laser systems for flexible weld edge preparation on different sheet thicknesses

Published 14.12.2022 | Erich Wörishofer

Company profile:

Ferro Service Sp. z o.o.

Poleska 52

66-620 Gubin

Poland

Ferro Service Sp. z o.o. is a metal and steel processing company based in Gubin, Poland. The company was founded in 2020 to provide the companies involved – such as Ferro Umformtechnik GmbH & Co. KG and the component manufacturer TEKRA Sp. z o.o. – with customized components.

www.facebook.com/Ferro-service

Fiber laser system with a working area of 3,000 x 1,500 mm
Ferro Service Sp z o.o invested in two fiber laser systems for rapid production of precisely reproducible series parts for flexible bevels on different sheet thicknesses. Each of these systems has a shuttle table with a working area of 3,000 x 1,500 mm.

Machine profile:

2 x MSF Pro series

Working area 3,000 x 1,500 mm
Laser rotator for weld preparation up to 45° with auto-calibration feature (ACTG®) + 4 kW laser source
Automatic shuttle table

The company Ferro Service Sp z o.o in Gubin (Poland) was launched in 2020: its core service is the series production of laser parts with and without bevel. For this purpose, the newly founded steel specialist started looking for state-of-the-art laser systems with bevel cutting heads. After an intensive search, they found what they were looking for in MicroStep and the MSF Pro series. Two fiber laser systems with a working area of 3,000 x 1,500 mm produce in multi-shift operation right from the start.

Crane arms, aerial work platforms, vehicles: the parts produced by Ferro Service Sp z o.o are used in a wide variety of industries and often perform heavy-duty work. The Gubin-based metalworking specialist was founded to support the companies involved – such as Ferro Umformtechnik GmbH & Co. KG and the component manufacturer TEKRA Sp. z o.o. – with customized components and to free up more capacity for other tasks.

Hall one in production, two further halls in planning

Production of the newly founded company started in March 2020, in a new hall on 2,200 square meters. Two further halls were planned at the same time. The second hall with more than 2,600 square meters is currently under construction and will be completed at the end of June 2022. The focus here is on automated production. At the end of the project, a total of around 8,000 square meters of production space will be available. There were 44 employees at the start, and two years later there are already more than 75. "Our strength is that we can offer complete mechanical processing," says Managing Director Matthias Bijkerk. After all, shareholder Ferro Umformtechnik is one of the technology leaders in the design, machining and processing of sheet metal, components and assemblies.

Laser parts with bevels in great demand

The heart of Ferro Service Sp z o.o's production is MicroStep's laser technology. "Our main focus is on laser parts with bevels. We also offer plasma and oxyfuel cutting, bending of parts and mechanical processing. For example, we supply 80 to 90 percent for crane jibs," Bijkerk said. With this combination of different technologies and a wide range of processing, Ferro Service can meet many requests under one roof. "This has given us a truly unique position in the market for the production of small parts, which customers appreciate," explains Matthias Bijkerk.

When it comes to 3D laser cutting, the company relies on two congruent compact 3D laser cutting systems from the MSF Pro series with a working area of 3,000 x 1,500 mm. "We were looking for an effective, state-of-the-art laser system with a 3D head to set up automated production," Bijkerk looks back. Through several channels, the decision-makers searched for suitable solutions, dealt with different manufacturers. Two remained in the running at the end. "Just when it comes to suppliers for laser applications with bevel heads, many drop out," Bijkerk knows. Many meetings, a visit to MicroStep in Bratislava, live demonstrations, creation of sample parts and a price analysis of the two manufacturers under consideration finally led to a decision for MicroStep and two fiber laser systems with laser rotator. These are to be supplemented by a handling and storage system in a later project planning and thus be further automated.

The two CNC fiber lasers are mainly used to process series orders in three-shift operation. Fine-grain structural steel, high-strength and wear-resistant materials are applied. The processed sheet thicknesses are mainly in the range from 1.5 mm to 15 mm. 20 mm have also been successfully tested, but above these material thicknesses Ferro Service prefers to use a plasma oxyfuel cutting system – for thicknesses up to 100 mm.

The start has been successful, and the two fiber laser systems have been operating effectively for almost two years. "The bottom line is that we are very, very satisfied. It's a really good fit."

"We were looking for an effective, state-of-the-art laser system with a 3D head to set up automated production. The bottom line is that we are very, very satisfied. It's a really good fit."

Matthias Bijkerk,
CEO| Ferro Service Sp z o.o

OVERVIEW OF THE HIGHLIGHTS OF THE TWO IDENTICAL LASER CUTTING SYSTEMS MSF:

Fiber laser system with a working area of 3,000 x 1,500 mm

The company Ferro invested in two CNC cutting systems with fiber laser of the MSF Pro series for sheet metal processing. The MSF Pro stands for extraordinary dynamics, high precision and contour accuracy as well as a high degree of automation. A shuttle table with enormous shuttle speed reduces expensive downtimes of the system. The working area is 3,000 x 1,500 mm. As filter system, a Beuting cartridge filter system was integrated.

Laser rotator for 3D cutting for weld edge preparation up to 45°

The decisive criterion for Ferro in choosing the laser cutting system was the option for 3D cutting. Compared to a 2D laser head, the MicroStep laser rotator is equipped with two additional rotation axes – the non-contact distance control guarantees consistent nozzle distances and thus optimum cutting quality even when the cutting head is tilted. The new laser rotator can be used to apply simple V seams as well as complex X, Y, or K seams with micro joints to different materials. As laser cutting head, a Highyag BIMO FSC has been integrated. For the laser source, the company relies on a new YLS 4000 AMB from IPG.