5-Axis Machining for Precision Mold Production

OM.AS S.r.l., based in northern Italy, specializes in high-precision parts and mold production for the automotive, food, and pharmaceutical industries. The manufacturer faced increasing market demands for precision, complexity, and sustainability in the production of large free-form surfaces. Growing competitive pressure required more efficient manufacturing processes. To maintain a strong market position, the company needed a technical solution to reduce setup times and avoid scrap during the production of complex, one-off aluminum molds, particularly rotational molds.

Implementation of 5-axis simultaneous machining
To address these operational challenges, the company implemented large gantry machines from DMG MORI. The production facility integrated three DMU 270 P and three DMU 210 P models, operating around the clock to process heavy and complex workpieces. These machines utilize 5-axis simultaneous machining technology, supported by centralized CAM programming and large tool magazines. The technical setup also includes integrated in-process measurement technology and digital process monitoring through a dedicated messenger system to optimize manufacturing workflows and detect deviations early.

Unattended production and increased reliability
The deployment of 5-axis simultaneous machining enabled the manufacturer to produce complex workpieces in fewer setups, significantly reducing setup times and machine downtime. The integration of in-process measurement increased overall process reliability, leading to a reduction in scrap and lower production costs. Digital machine monitoring provided faster response times for operators. Furthermore, the automated capabilities of the gantry machines facilitated unattended overnight machining, resulting in higher productivity and increased machine utilization. "Thanks to 5-axis simultaneous machining, we produce our workpieces in fewer setups and do so unattended overnight," stated the company regarding the optimized processes.

Edited by Maria Brueva, Induportals editor – adapted by AI.

www.dmgmori.com