Kusters Precision Parts assured of flexibility and productivity with hyperMILL

With 21 hyperMILL programming stations, Kusters Precision Parts in Oss is assured of efficient and flexible production. The supplier specializes in machining complex and high-precision components found in the semiconductor, medical, optical and aerospace industries, among others. "We make small series (and) single pieces. The goal is to produce these workpieces reliably in the shortest possible time. The hyperMILL CAD/CAM software plays an important role in this."

Kusters Precision Parts was founded in 1973 as a supplier of high-tech components. Since then, the company has grown rapidly. So hard that in 2021 the company moved to a new building location with a super-modern production area of no less than 7,500 m2 and its own clean room of 400 m2. The machinery now consists of some 36 machining centers, ten erodeers, and more machines are planned. Last year alone, as many as thirteen machine tools were purchased.

"We expect great industrial growth in the coming years due in particular to the semicon industry. Therefore, we are investing a lot in new machine tools that are even more accurate and have even more functionalities. But like the rest of the manufacturing industry, we are also struggling to find skilled workers. In order to facilitate this growth despite the shortage of people, we are investing in automation and process optimization. In addition to robotic cells and other automation solutions, we also optimize with software. Various smart functionalities in the hyperMILL CAD/CAM software, for example, help to increase the efficiency of the programming process and thus productivity," says Olaf Heijers, general manager at Kusters Precision Parts.

Automation in CAM

One of the hyperMILL functionality that Kusters uses is Automation Center. This solution is part of the hyperMILL automation technology that helps reduce programming times, standardize processes and improve overall turnaround times. Where standard CAD/CAM automation of hyperMILL allows the automated programming of similar geometries, such as recurring form elements, features like boreholes or chambers and repetitive processes, Automation Center offers even more possibilities for setting up individual automation projects. With it, Kusters has, for example, digitized all fixtures and given them a central location on the server. This allows programmers to select a predefined fixture for each machine. According to Olaf Heijers, this standardization saves a lot of time because components can be programmed and simulated within the shortest possible time. In addition, the risk of human error is minimized since everyone works with the same data.

Full transparency

In addition to all fixtures being in hyperMILL have been brought, Kusters is also working to digitize all machining tools. Because the supplier strives for maximum flexibility, most machine tools are equipped with large tool magazines with space for hundreds of tools. It is quite a job to structure these. By placing all tool data in a central tool library, complete transparency is created in tool management. Moreover, from then on everyone works with the same tool parameters. This also speeds up the programming and production process and reduces the risk of errors. "The goal is to make all data crucial to the production process centrally accessible. Besides reducing the chance of errors this way, we are also building a knowledge database. You often see in practice that people work with different tool parameters. Some are careful and work with too low a feed, while others overload the tool. By using a central database with defined parameters, programmers know what data they have to work with. This is also important for the future, because expert knowledge is slowly disappearing due to an insufficient influx of new technicians. In order to be able to continue making our high-tech products in the future, we must therefore record professional knowledge and standardize processes as much as possible," says Johan van den Heuvel, milling team leader at Kusters Precision Parts.

Simulation gives certainty

Stefan van Aalst, director of OPEN MIND Benelux adds: "The moment you have all data of machines, fixtures and tools digitally available, it is possible to perform a reliable simulation. OPEN MIND's VIRTUAL Machining Simulation module enables communication with the machine, providing Kusters with simulation accuracy that matches the real machine. When the NC program is generated, our VIRTUAL Machining knows the CAM programming on the one hand and all machine specifications and constraints on the other. Thus, while generating the NC code, we can optimally adapt the movements to the machine, find the best settings and eliminate unnecessary movements. All in all, this thus not only prevents collisions, but it simultaneously optimizes the NC program, resulting in shorter machining times."

Moving with innovation

Johan has worked with several CAD/CAM packages in the past, but is ultimately most excited for the performance of hyperMILL. Initially, the ease with which five-axis cycles could be programmed brought a great advantage.

Johan van den Heuvel says: We mainly produce complex parts that require regular five-axis machining. Because we make single pieces and small series, the speed of programming is crucial to meet short delivery times. Moreover, we cannot afford imperfections because we work for very demanding industries. With the various five-axis strategies in hyperMILL we can program challenging geometries, free-form surfaces and deep cavities easily and quickly."

Since the commissioning of hyperMILL has added many new functionalities, according to Olaf Heijers. "We are in the top segment so we are always looking for solutions to automate and optimize processes. If you don't do this, you won't make any progress." Johan van den Heuvel continues: "Because developments follow each other at lightning speed, it is a challenge to keep up. OPEN MIND therefore gives training courses twice a month to keep up with the newest functionalities of hyperMILL under the spotlight. That really adds value. For example, we have already benefited very much from Virtual Machining and we are currently keeping a close eye on PMI's developments. In addition, it is of course nice that we can rely on a partner who supports us in terms of both knowledge and service."