Cybaman makes full use of a System 3R pallet system in its precision machines

Joe McLean, the founder of Cybaman Technologies, applied for his first patent over 25 years ago. This patent was the basis for the development and production of the multi-axis, automatic machining centres that would revolutionise both rapid prototyping and short-series production.

From the very beginning, by radically reducing the distance between the workpiece and the cutting tool’s centre of rotation, Joe sought to minimise the size of his precision manufacturing machine. Eliminating the large offsets generated by large axial movements would give far better control of the chip removal process. Thanks to its low profile, System 3R’s Macro zero-point system and its only 23 mm high pneumatic chuck made it possible to position the workpiece nearer the cutting tool than ever before. The compact pallet system gave the stability necessary when machining at spindle speeds of up to 50,000 revolutions a minute.

Recognition of the innovative technology in the Cybaman machine was virtually immediate. It received a deluge of British awards (Prince of Wales Award for industrial innovation, Archimedes Award for innovative design, Millennium Products Award, etc.) and was presented on the famous Tomorrow’s World television programme. Far-sighted entrepreneurs in the jewellery industry were the first to invest in the fully automatic Cybaman machines. These machines delivered exactly the high precision that characterises the fine detailing of the industry’s products. The Macro pallet system includes the 3Refix reference system. This guarantees repeatable precision. Furthermore, by eliminating time-consuming set-ups and expensive idle time when a workpiece has to go through various machining processes, it increases productivity.

Development of the Cybaman Digital Manufacturing System has now resulted in the first 6-axis three-dimensional multipurpose machine (3D Replicator with CNC positioning) for both stock removal and stock adding processes. It includes high-speed machining (milling, drilling and grinding) of three-dimensional metal components and a laser that “builds up” components. “Building up” and using stock removal to achieve the optimum finish for a component are critically important in rapid prototyping and one-off production. This is supremely the case in the manufacture of moulding tools.

Once again, a System 3R pallet system has proved invaluable in delivering the precision and tight tolerances now demanded by the aerospace, automotive and medical technology industries. Tolerances here are less than 10 µm.

Robotic handling equipment in the Cybaman machines (e.g. an 11-position pallet changer that is also based on the Macro pallet system) enables reliable, unmanned, lights-out production. Such increases in capacity maximise machine utilisation and productivity. This significantly lowers production costs and considerably improves the economics of manufacturing in an extremely global and competitive market.

Cybaman and System 3R are, in their own ways, both at the cutting edge as regards developing new technologies that ultimately benefit their respective customers. Both companies’ innovations have certainly enabled considerable steps forward in the production of precision parts all around the world.