Mould Insert Fabrication with Integrated Toolroom Cell
Overview
A pioneering 'Lights-Out' manufacturing workflow that eliminated the error-prone 'Human Bridge' between digital design and physical production. By integrating RFID-based palletization with a unified CAD/CAM environment (Siemens NX), we achieved a seamless 'Art-to-Part' data chain. The system allows a mould insert to be designed, simulated, and machined to <5µm tolerance without a single manual data entry point.
The Challenge
Precision tooling has historically suffered from the 'Analog Gap'—where precise digital designs are manually transcribed into machine coordinates. This manual zero-point setting is the primary source of dimensional errors and machine idle time.
- Achieving tight tolerances (<5 microns) on hardened steel inserts.
- Calibrating the digital twin simulation to match physical machine kinematics.
- Eliminating manual zero-point setting errors.
The Solution
Deployed a 'Cyber-Physical System' using System 3R macro-holders and offline CMM presetting. This decoupled setup time from run time, enabling a 100% Digital Thread where the CNC machine inherits its coordinate system directly from the RFID chip on the workpiece.
System Architecture
The 'Art to Part' workflow removes human intervention from the setup phase. 1. Digital Twin: The entire machining process is simulated in Siemens NX to verify collision-free toolpaths. 2. Off-Machine Presetting: Workpieces are mounted on System 3R pallets and measured on a CMM. Offsets are written to an RFID chip. 3. Robotic Integration: The System 3R robot loads the pallet into the CNC. The machine reads the RFID offsets and begins machining immediately.
Digital Design
CAD (Design) & CAM (Programming) in Siemens NX. Collision verification via Digital Twin.
Presetting
Workpiece mounted on 3R Pallet. Measured on CMM. Offsets saved to RFID.
Automation
Robot loads pallet. CNC reads RFID offsets. Zero manual probing required.
Machining
High-speed 5-axis milling (Mikron HSM). Finished part ready for inspection.
The Advantage
Traditional Workflow
- Manual data entry of X,Y,Z offsets (Error prone).
- Machine idle during setup (Downtime).
- Disconnected processes (CAD -> Paper -> Machine).
- High risk of tool collision.
Proposed Solution
- RFID transfer of offsets (Zero error).
- Setup happens external to machine (SMED).
- Digital Thread (CAD -> CAM -> CNC).
- 100% Verified via simulation.
Key Features
Seamless CAD/CAM/CNC Chain
Direct G-code transfer.
Off-Machine Presetting
Measuring tools and workpieces while the machine is running.
Digital Twin Simulation
Verifying toolpaths virtually to prevent crashes.
Impact & Outcomes
Reduced machine setup time by 40%, effectively unlocking 'Single-Minute Exchange of Die' (SMED) for high-mix low-volume tooling. The system proved that micron-level precision is reproducible not through operator skill, but through deterministic process control. This workflow served as a blueprint for the modern 'Integrated Toolroom'.