CASE STUDY

Precise CNC machining of advanced 3D models

The Lambda GT machining center by FANUM is equipped with Siemens’ fully digital SINUMERIK ONE numerical control system. It delivers excellent performance wherever a high level of stability and machining precision is required under all CNC machine load conditions.

FANUM is a leading European manufacturer of CNC machines for processing materials such as wood, plastics, and aluminum. The company offers dozens of machine types tailored to customer needs. These machines are widely used in the production of specialized products, furniture components, as well as houses and wooden structures.FANUM’s flagship product is the technologically advanced Lambda GT five-axis machining center.

Construction of the device and its application

The Lambda GT machining center produced by FANUM is designed for complex machining of spatial components. The machine enables precise CNC milling of models used in the production of laminated elements, injection molds, and casting molds. It allows 3D machining in a five-axis interpolated system of materials such as wood and wood-based materials, plastics, polymer composites, laminates, resins, and aluminum. It can be used both for heavy-duty machining and for processing various types of molds and 3D models made of soft and lightweight materials, such as polyurethane foam or polystyrene.

“The Lambda GT machining center is used for precise CNC milling. Our customers use it, among other things, for milling 3D casting models, manufacturing molds for thermoforming in plastics processing, and working with GRP laminates used in the production of aircraft, cars, and boats,”
explains Szymon Skorupski, Head of the Sales Department at FANUM.

The Lambda GT machining center enables 3D machining in a five-axis interpolated system across a wide range of materials—from wood and laminates to metals such as aluminum.

Important components of the machine tool include the milling head, the worktable, and the mobile gantry. The machine does not require additional protective enclosures.

Lambda GT is a five-axis CNC milling machine featuring a heavy base that serves as the foundation for the worktable and the kinematic system of the portal supporting the milling head. It is built as a dual, integrated spatial gantry driven by two synchronized servo motors located on both sides of the machine table. A key element of the machine tool is the aforementioned table, the size of which may vary depending on the application, ranging from 3×2 m up to 20×3 m. Another important component of the device is the mobile gantry with a Z-axis travel ranging from 700 mm to 1500 mm.

FANUM has many years of experience in designing this type of equipment. Over more than a decade, this type of machining center design has proven highly effective in the production of casting models, large-sized aluminum profiles, and in composite machining. The machine is suitable wherever an open design and ease of loading and unloading the worktable are important.

"The Lambda GT is equipped with a dual mobile gantry, which ensures unmatched rigidity and a compact structure. As a result, the machine does not require additional protective enclosures. These functional design features are particularly important when machining highly precise and complex models made of hard materials,”
emphasizes Wojciech Wójcik, co-owner of FANUM.

SINUMERIK ONE and the digital twin

The Lambda GT machining center has been equipped with the latest, fully digital Siemens numerical control system. SINUMERIK ONE, the SIMATIC S7-1500F PLC controller, and SINAMICS S120 drive systems are responsible for comprehensive machine control, execution of technological machining programs, and ensuring machine tool safety, while simultaneously meeting modern standards of production digitalization.

The SINUMERIK ONE numerical control system from Siemens sets a new standard in the increasingly digitalized world of CNC manufacturing. Our client, an international company in the metrology technology sector based in the United Kingdom, had no doubts during the prototyping, configuration, and procurement process of a new machine tool for research and development purposes that SINUMERIK ONE was the control system capable of meeting all technological requirements.

Szymon Skorupski, Head of Sales Department, FANUM

A key feature of the solution provided by FANUM is not only the precise machining process ensured by the Lambda GT, but also the ability to use advanced simulations already at the technological program preparation stage. Thanks to the functionality of the software and the excellent integration of the measurement software with the SINUMERIK ONE control system, it is possible to implement a wide range of measurement cycles, as well as to create new ones.

“The machining program is prepared in CAD/CAM software. The customer then has the possibility to verify the machining process and machine behavior through simulation in the virtual environment of the machine tool’s digital twin. If any corrections to the machining program are required, the digital twin enables accurate remote simulation of the program’s performance and the introduced changes,”
— explains Wojciech Wójcik.

The Lambda GT machining center makes use of a range of Siemens solutions, including SINAMICS S120 drive systems, the SIMATIC NANO BOX PC industrial computer, and SITOP stabilized power supplies.

The device uses the fully digital SINUMERIK ONE numerical control system, which proves effective wherever a high level of machining stability and precision is required.

The SINUMERIK ONE system, the SIMATIC S7-1500F PLC controller, and SINAMICS S120 drives are responsible for comprehensive machine control and the execution of technological machining programs.

A digital twin created on Siemens platforms – Create MyVirtual Machine and Run MyVirtual Machine, along with the SIMIT module and NX Mechatronic Concept Designer (MCD) – enables the simulation of discrete signals and continuous processes. These tools allow verification of the operation of digital and analog inputs/outputs cooperating with the machine’s sensors as well as its peripheral devices. They also provide the capability to reproduce the full physics of a rigid body, including inertial forces acting on the kinematic system in a machine tool.

“Considering the characteristics of FANUM’s products, these are innovative, tailor-made machines. In the case of the Lambda GT machining center, the digital twin ensures full replication of the machine’s actual numerical control system, the operation of the PLC controller, drive data processing, the operator panel, as well as peripheral devices,”
says Karol Staworko, Director of the Sales Development Department at Siemens Poland.

“Thanks to this, the customer gains the ability to verify the correctness of the production process in a virtual environment and does not have to learn from mistakes. This makes it possible to accelerate the implementation process of a new part for machining, minimize downtime and machine changeover time. It also significantly reduces the risk of machine collisions. Most importantly, thanks to the machine tool’s digital twin, the customer is able to determine machining time with the highest level of accuracy achieved to date,”
he adds.

FANUM’s collaboration with Siemens

FANUM engineers emphasize the quality and reliability of Siemens solutions used in the company’s machines, including the Lambda GT.

For both us and our customers, the high quality of Siemens components, their innovation, and the ease of access to technical and technological support as well as service, including remote support, are essential.

Wojciech Wójcik, co-owner, FANUM

“Currently, we cooperate with Siemens in the area of premium-class and special-purpose machines. Our machine portfolio is expanding, and new customers with new challenges are emerging. With Siemens—their hardware offering, software, and support—we know that modern market expectations are within our engineering capabilities. This ensures sustainable growth for both our company and our customers, while aspects such as efficient and cost-effective production as well as cybersecurity are maintained at the highest level,”
adds Wojciech Wójcik, co-owner of FANUM.

In 2023, FANUM used the latest Siemens SINUMERIK ONE control system for the first time in its five-axis machining center, among other reasons due to a customer requirement. Throughout the entire machine production process and the subsequent implementation at the customer’s site, FANUM engineers received full support from Siemens.

Machines created by FANUM are “tailor-made” solutions, fully adapted to the company’s customers’ needs.

The implementation of the SINUMERIK ONE control system has opened the door for us to a wide range of potential customers in the automotive and aerospace industries, for whom the use of this solution is a necessary requirement. These few joint implementations have made us realize the very high versatility and flexibility of the SINUMERIK ONE system, as well as the wide range of its possible applications. This control system performs excellently in these areas.

Szymon Skorupski, Head of the Sales Department, FANUM