Oscarmax: Highly rated & competitive EDM manufacturer

The prominent manufacturer who starts a revolutionary idea for contemporary EDMs

What does the years 2016-18 entail? For a number of manufacturers, it is a volatile period of time given the harsh waves of trade war and now escalating into a technological war of two major economies. The machine tool export of the island have declined 10.3% in January - April, 2019, compared to the same period of time in 2018.

But the storm stayed out of the door of Oscarmax. Having grown 12% in revenue within three years, their performance goes in reverse of the general trend. They revolutionised the traditional machining scope of Electrical discharge machining (EDM).

This cover story takes readers into the world of Oscarmax, and inspect the abundant but subtle energy in their ingenious innovation of the 35-year-old EDM manufacturer. International Metalworking News for Asia interviewed OSCARMAX EDM Business Department Manager Jason Ho, he guides us through the adventure of Oscarmax.

The lack of creativity in EDM machines prompted founders to dedicate into the field

During the years of establishment of Oscarmax, EDM technology is involved in the high-flying new field of techniques that emerged in Taiwan, but the siblings, also the founders of Oscarmax recognized that the technology of EDM have much greater potential in delivering the diverse side of it, and since then, they had made two bold revolutionary moves to redefine the contemporary technology of EDM and broaden the applications of EDM on using evidence based methodology.

Toppling the industry with disruptive EDM technology

The first innovative move is in releasing EDM technology with the ongoing 4th industrial revolution. In the age of technology paradigm moving forward fast, CNC automated EDMs are constantly redefined. In particular in the field of aerospace manufacturing, through integrating with clients’ high-end need, five-axis simulated cutting, and multi-channel electric discharge loop and other courageous ground-breaking technologies.

‘We have put much effort in exploring the fundamental potential of EDM since our establishment,” Oscarmax emphasized.

The much anticipated project that Oscarmax is working on is an unmanned airplane components manufacturing line with AIDC.  About 80% of the production in this automated manufacturing line relies on EDM machines for 24-hour-production. It could be said to entail great significance in the manufacturing industry - on the progression that EDM being used directly to manufacture aircraft components. In the past, the major application of EDMs is in making mould-dies on automobiles and home appliances. However, after optimizing and broadening the capacity in materials processing, EDMs can be used in petrochemical and specialised key components production, such as airplane engine diffuser OGV, which opens up the great era of EDMs. Jason considered that once the first EDM automated airplane components manufacturing line is completed, it will create paramount demands in ‘using EDM produce components’.

Highly in-house produced mechanical structure + automation = super high value

You might wonder how the ‘revolutionary manufacturing adds value to producers. Jason explains that the new version of EDMs could resolve the traditional challenges that milling machines brings. Furthermore, the machining limits that milling machines have on shapes are almost non-existent for EDMs due to the freedom in creating flexible multi-shape tools in accordance to work piece features and simplify the complex cutting path. S500 CMAX - S860CMAX combines two 5 axes simultaneously movement EDMs and a tool storage system that contains 84 electrode tools as a solution for the leading Taiwan aircraft company EVA air.

The pursuit of evidence-based spirit and top class pre-purchase service

The second pioneering step is the spirit of creating an evidence-based scientific spirit as one of the first EDM manufacturers in doing so, in particularly on establishing a database for materials. Recently the company began to ask clients and potential buyers to supply a range of difficult-to-machine materials. They then experiment on processing materials that EDMs have never been machined before, and seek to find the best parameter.  Jason stressed that materials are the core condition that affect performances of machining. Their immediate goal now is thus to break the machining boundary of high tensile metal, such as Inconel and Titanium Alloy, and various Tungsten steel. Oscarmax currently spends a great amount of time in testing new materials to understand the features and properties and the best machining parameters. These data is escalating in becoming the first EDM production database built by Oscarmax.

New system EtherCAT allows innovation to be realised

Presently, Oscarmax embedded EtherCAT (Ethernet for Control Automation Technology), a German Ethernet-based fieldbus system. EtherCAT is a strong automation solution, making it easier for delivering data and machine communication. The advantages of EtherCAT exist in its PCB and communication feature that released greater freedom in mechanical and structural design. Jason explained that the improvements are thus applied in the renewed Sinker EDM and Micro drill EDMs, the new designs practices the ideal solution for extremely compact and efficient equipment.

How will Oscarmax treat its brand on valuing-up as a manufacturer of over 50 year-old? The answer is: “Integrate energy of the entire company and execute in full-speed. Attending top class machine tool trade shows.”  - Oscarmax, 2019.

After decades of perseverance and energy built-up, Oscarmax is enjoying the result of constant technology innovation and customer service. They hold the attitude of planning ahead, new series of machines already awaits. Asking about the secret of succeeding in the manufacturing sector, Jason says internal efficiency and using the resource from the abundant and rich industrial chain in Taiwan is essential and enables the company in performing more wisely and flexibly.

This year, Oscarmax participated in the most reputed machine tool trade show – EMO Hannover. With 17 agents in Europe, they wish to advocate their strong presence and service in Europe.

Finally, the ability to learn, integration and smart machinery are the crucial principles for a senior but energetic company like Oscarmax. They anticipate that now knowledge and creativity from the entire company and colleagues would be injected in the creation of more original and revolutionary EDMs.

Factory Digitization Live Working Demo at Omron ATC

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Additive manufacturing, a driver of thoughtful change

Markus Lindemann, Head of Laser Technology Asia Pacific, TRUMPF

Additive manufacturing (AM) is one of the hottest topics for designers and manufacturers today. It has tremendous potential to influence products designs in many industries. But how do we get there? To those who can benefit from it must take advantage of this technological advancement, whilst others need to brainstorm ways that perhaps could help them out in one way or another.

In an exclusive interview conducted by Kathryn Gerardino-Elagio of INTERNATIONAL METALWORKING NEWS FOR ASIA, Markus Lindemann, Head of Laser Technology Asia Pacific, TRUMPF Pte Ltd shares his proficiency in additive manufacturing and encourages customers to have an open mind set. Markus is not inciting a big bang approach and throwing money. Instead, he urges customers to try new things and improve along the way. Many are increasingly interested in new technologies with clear use case, but most are still not ready to invest broadly. Markus’ goal is to educate readers about the potential value of additive manufacturing.

IMNA: What technologies are you developing that will allow for the ubiquitous use of additive manufacturing?

MARKUS: TRUMPF is developing two additive manufacturing technologies: Laser Metal Deposition (LMD) / Laser Cladding which is a powder nozzle technology and Laser Metal Fusion (LMF) which is a powder bed technology.

The advantage of Laser Metal Fusion is that it allows you to build complex and unique-shaped metal 3D parts. But the real challenge here is that once you start optimising your parts using power bed technology, you can’t go back to conventional technology. That means if you decide to optimise the advantage of LMF, you can’t change and use any other manufacturing technology. Therefore, you must have an open mind set in order to design the most competitive part by using additive manufacturing. Any compromise will lead to a higher cost.

The advantage of Laser Metal Deposition is to build up material on a prefinished 3D parts and mix different material within the LMD processes. The build rate of LMD is usually higher since the accuracy and surface roughness are typically not as good as of an LMF process. LMD is also very often used for hard facing of surfaces in order to increase the live time of new parts.

When you talk about AM technology, you must always think about the whole process chain and not just having subtractive processes and additive processes. Think of what you need to do in order to get the final part. Sometimes there are assembly parts that have four, five or even more different production steps. With additive you might have just have one part which will provide you the same result. You reduce the complexity in the manufacturing process chain and you are able to make the parts more compact with less weight.

IMNA: Describe how additive manufacturing will now change the way companies in Asia manufacture.

MARKUS: Additive manufacturing is not only for Asia. It’s a global trend.  Europe, America and countries in Asia are heading into this direction because of they see the unique advantages of additive manufacturing technologies. AM will play a pivotal role in complimenting traditional subtractive manufacturing, but it needs to be developed. It requires first of all open minded people in the management and design departments for it to become a normal production technology; like what we have in today’s machining, EDM and even laser cutting.

IMNA: Characterise the importance of additive manufacturing to companies in Asia.

MARKUS: If you want to be competitive in the near future, you need to invest into AM because the benefits for certain parts are tremendous; and if you are not able to offer this technology, you will be just out of the game. All companies in Singapore are taught how to use additive manufacturing to optimise their components and parts in the future. This is a long term goal, and as I said it needs people who will learn what it means to build in additive and adapt this knowledge to their parts’ design. TRUMPF is supporting this idea. We train people and share information about additive technologies in order to have more individuals in this field changing the course of designing. The Singapore Government is doing the same including institutes such as ARTC, IMRE and SIMTech, they all support clients to optimise their parts for additive manufacturing. The more people know about the advantages of this technology, the higher the chance that they are able to change the geometry for additive in the future.

IMNA: Can hybrid additive become cost-effective? 

MARKUS:TRUMPF have a long history of hybrid machines, we have many years of experience developing punching machines with a laser cutting head - this is also hybrid. For some industries it is quite interesting, especially when a company needs to be flexible and they have low production volume. But there are also big players who are running a couple of machines of each type.

In my point of view, it is better to have a pure additive machine and a pure subtractive machine. The hybrid machine is just interesting for a certain group of customers that need to be very flexible. For the customers with huge volume, I always think it’s better to have different technologies with different machines. The advantages of having a combined machine - like Okuma combining milling and laser cladding - can be remarkable, if you really have an advantage in combining these 2 processes within one machining process. From my point of view these applications are quite limited today but then again: we never know what’s coming next. New possibilities will lead to a new demand, also for hybrid machines.

IMNA: Talking about laser, would you say that laser systems were running in factories long before anyone was talking about Industry 4.0? How is laser fundamental for Industry 4.0?

MARKUS: Industry 4.0 is a development in any manufacturing process, not only for lasers. For lasers it is especially interesting because lasers are very flexible. Since it’s a flexible tool, you can just change the programming and do different things with one laser source. At TRUMPF, we offer a machine that can do welding, cutting and laser cladding. What you need is just to have the machine configuration for 3 technologies and you can switch between these 3x laser technologies very fast. With Industry 4.0 you might be more flexible to use these different technologies more efficient in your factory.

IMNA: What are the biggest advantages of lasers?

MARKUS: The biggest advantage of laser is flexibility. There are so many laser applications outside the manufacturing process that shows you how powerful laser is. TRUMPF is just focusing in lasers for industrial production and that’s already a huge topic in the automotive industry, medical devices, semiconductor, electronics businesses and many other industries. This industry is growing every year, and every year there are new applications coming up that has never been done before and thought-provoking. This enables the producer to create smaller and flexible modern devices with new features.

IMNA: With TRUMPF solutions in mind, what can you advise our readers in Asia who are thinking of implementing Industry 4.0 in their shop floors but are hesitant?

MARKUS: The major point is to be open for cooperation and share the information with experienced people. If you just look at your own data, you may have a limited database; but if you share your data with a professional company who has success with other companies as well, they can analyse your data and give you feedback – this is much more powerful than any company who do it by themselves. People in the management, especially in the IT departments, should be open for that. Level the risks and the advantages, and see how beneficial these advantages are for your company as compared to the risks.

TruPrint 1000

Hypertherm: Turning a tech eye on Philippines

Wagner Turri, Sales Leader – South East Asia & Taiwan, Hypertherm

The Philippines is expected to grow faster than South East Asia as a whole over the next two decades, with overall GDP expanding by 4.8% per year in the 2014-33 period,” according to a report from Deloitte. There are reports that predict some companies are set to relocate their production from China, their traditional base, to the Philippines and neighbouring countries in South East Asia. These measures will help sustain the growth of the industrial sector in the years to come.

Although opportunities are vast in the Philippines, tapping the industrial manufacturing market will require nonconventional strategies. Industrial base is expected to continue expanding in the near term. But transition to high-complexity manufacturing is not going to happen overnight. 

In an interview in line with the recent Philippine Die & Mould Machineries and Equipment Exhibition (PDMEX), International Metalworking News for Asia spoke to Wagner Turri, Sales Leader – South East Asia & Taiwan, Hypertherm.

IMNA: Which Hypertherm products were highlighted at the show? What are the special features of these products and how are these different from those available in the market today?

Wagner Turri: At the PDMEX trade event, we worked with our channel partner, Fuman Industries Inc. (Fuman), to showcase Hypertherm’s Powermax® range. The Powermax family is a series of highly portable, professional grade air plasma cutting and gouging systems. Built to withstand heavy-duty use in challenging industrial environments, the Powermax systems are an ideal choice for hand or automated cutting and gouging of any electrically conductive metal. Offering the best performance in its class, the Powermax systems feature state-of-the-art consumable technology that delivers faster speeds and better cut quality to help users enhance efficiency. Less experienced users will find the Powermax systems easy to operate especially with its high portability, simple controls, and a stable plasma arc.

The Powermax offers unique applications such as attachment or lug removal with our FlushCut consumables. The patented design of the FlushCut consumables allows users to cut as close to the base as possible, without piercing or damaging the workpiece, and increases efficiency compared to other solutions like oxyfuel, carbon arc gouging, or traditional plasma cutting tools. In addition, the Powermax is also equipped with straight torches that can be used on track burners and carriages for bevel cutting profiles — improving bevel cut quality and cutting speeds over oxyfuel technology. With the Powwermax45® XP, customers can also enjoy marking capabilities, which is suitable for marking on plates and parts for quality control purposes or to indicate welding positions.

One of the key products highlighted at the show was the Powermax30® AIR system — the smallest, lightest handheld plasma cutting system in its class that delivers big on performance. It includes its own built-in air compressor, so one can use the Powermax30 AIR anywhere there is single-phase power. Users will enjoy the ease of use — just plug it in, attach the work clamp, and the system is ready to cut.

IMNA: How important is R&D to Hypertherm for the development of new products? Did the company tap on special skills, special production processes, or innovative machineries/techniques to manufacture the products?

Wagner Turri: With 50 years of experience and close to 500 global patents, Hypertherm dedicates more resources to industrial cutting research, development, and testing than any other manufacturer in the world. Our company’s continuous advances in technology provide features that customers need and have come to rely on. For example, one of the key attributes our customers appreciate most is the increased consumable life, through which they are able to enhance productivity and lower their cutting costs. Hypertherm’s parts are designed and optimised for each torch, power supply, and application. These parts are subjected to extensive tests — assuring customers that their equipment will deliver optimal life and cut quality.

IMNA: What are some key trends that are shaping the metalworking industry? How have these developments impacted Hypertherm?

Wagner Turri: We anticipate more challenging times ahead for the regional metalworking industry, in which competitiveness will be driven by customer’s needs and prompt feedback for opportunities and improvements. Industrial automation and digitalisation are set to be the key drivers of change, and the climate would be more demanding in Asia Pacific due to future economic growth and the competitive landscape. This trend will propel the metalworking industry to set new norms, where product quality is considered a ‘standard’ feature and customers’ requests are influenced by positive experiences in their interaction with these products, services, or solutions.

Over the last few years, we have seen a growing number of solutions that encourage the introduction of automation and digitalisation to the metalworking industry. Technologies that are related to the Industrial Internet of Things (IIoT) are enabling companies to build up smarter job shops, allowing the industry to establish a smart machinery eco-system.

Automation and digitalisation embedded in the IIoT platform have given manufacturers enhanced equipment and process capabilities, and have supported them in improving production effectiveness and measures for cost management. In the last three years, Hypertherm has been addressing these industrial demands and trends with the development of a new set of plasma source and controllers, and by improving on-time operations support to customers. Our cutting-edge solution — the X-Definition™ plasma source and NC industrial controller — provides real-time feedback on performance to job shops via a Wi-Fi connection. This Wi-Fi connectivity enables metalworking job shops to connect to these machines with a single device (e.g. smart phone or computer) to collect data on machine performance and maintenance. In addition, our new set of NC industrial controllers can receive cutting nesting jobs through Wi-Fi. Furthermore, Hypertherm employs the most advanced communication protocol (i.e. EtherCAT) to provide faster information flow when our products are integrated with an automated solution, such as a NC plasma machine, for straight or bevel cutting, or a plasma robotic arm for 3D or pipe cutting.

Technological advances like these continue to elevate Hypertherm’s plasma cutting capabilities. In addition, our wide range of solutions for automation and portability include new sets of robotic cutting tools and applications, delivered by our new rotary sleeve mechanical solution and the introduction of our off-line robotic software. In this way, Hypertherm offers unmatched cut quality and precision (up to ISO 9013 Range 2) through our latest X-Definition class plasma system. This solution offers users reduced operation costs with its new electronic feature that extends consumable life, avoiding premature damage or misuse. With its new process technologies that deliver high cutting performance at optimal costs, our X-Definition plasma system is an outstanding example of how we are able to address the changes ahead for manufacturers.

IMNA: How important is the Philippines market to Hypertherm? Do you have any plans to expand your operations or market reach here in the Philippines? Where and when?

Wagner Turri: Hypertherm has been actively promoting its solutions across the Asia market, educating users on how its technologies can be beneficial to their business. We have been in the Philippines for more than 15 years serving a wide range of industries through a partnership with Fuman.

Over the years, we have observed significant year-on-year growth and expansion, through working closely with our customers from various sectors, including signages, construction, metal fabrication, and structural steel. We foresee our customers in the Philippines looking to be more competitive in their local market, especially with the wave of infrastructure projects coming up across the country. Our cutting solutions, promoted by Fuman at the PDMEX show, cover most of our customers’ needs, especially with regard to keeping operational costs low through leveraging on our technologies.

As the economy continues to grow across Asia, companies will continue to expand their operations, optimise to reduce cost, and expand capabilities to capture new markets. This will result in a continuous demand for efficient metal cutting solutions, and we look forward to new partnerships to meet those manufacturers’ cutting needs.

Hurco reveals expansionary plans in South East Asia

 

 Wai Yip Lee, General Manager of Hurco (S.E. Asia) Pte Ltd

Hurco is going through an expansionary and upgrading phase in South East Asia. In an interview Wai Yip Lee, General Manager of Hurco (S.E. Asia) Pte Ltd told Kathryn Gerardino-Elagio of International Metalworking News for Asia (IMNA) how the company is working proactively with partners in various markets to establish new technical centres for showcasing existing and new Hurco control technologies to end-users. Wai Yip revealed a series of upgrades being made to Hurco’s machining centres and lathes to enhance performance and introduction of new software features to make programming easier and more efficient.

IMNA: I knew you had an open house in Thailand sometime in May, how was the response? Did you launch any new machining centers?

Wai Yip: The open house held at our distributor, Thaimach’s showroom, was well attended by more than 60 visitors across various industries.  We worked alongside Thaimach’s key partners: Hexagon Group and Jaguura to showcase two units of Hurco Machining Centres, three units of Jaguura grinding centres and Hexagon range of metrology products.  We also had 6 other partners present to showcase their exhibits and present their products in a series of seminars.  The major brands represented at this open house include: Blaser Swisslube, Mitsubishi Hard Metal, Haimer, TRIAG, VERO software.

We take this opportunity to launch our new 3D Solid Model Import and 3D DXF Transfer software during this open house to demonstrate how our controller continue to innovate to improve customer’s productivity.

IMNA: This year, will you have another round of open house in Vietnam and Indonesia. Do you agree these open houses help you stay close to your customers and understand the different markets in SEA?

Wai Yip: We are planning two more open houses at our distributors’ technical centres in Q4 2019: ATP in Hanoi and PT Aransa in Jakarta.  These two new facilities will house two Hurco machines, a MAX5 demo console unit, critical spare parts, and relevant tools to facilitate machine demos and test-cuts.  The technical centre will act as a platform to reach out to end-users in these markets so that they could better understand the important link between our proprietary Winmax controller with the machines.  For a start, end-users can see how Hurco conversational programming could improve their productivity by reducing their set-up and programming time for high-mix, low volume parts.  For advance users, the Hurco MAX5 control is capable of processing large programs with complicated tool path for complex part geometries, such as high-speed machining and simultaneous 5-axis operations.

On a side note, I have also ensured that each technical centre is well equipped with its own coffee machine so that our customers can always enjoy a good cuppa over a business discussion or a machine demo.

IMNA: This open house concept seems to work well. What countries experienced most growth last year?

Wai Yip: We have seen encouraging sales growth in Singapore and Vietnam in the past year.  The growth from Singapore, a matured market, has been attributed to the growing interest and the adoption of 5-axis technology.  Meanwhile, our new partners in Vietnam have allowed us to engage the end-users more effectively so that we could understand their local requirements.  We will continue to work closely with our partners by investing more resources to support our growing customer base in Vietnam.

IMNA: You are promoting 5-axis CNC machining centers in the region. Do you see growth potential in this area for Hurco? Do you have plans to introduce new 5-axis models or expand the series?

Wai Yip: 5 axis machining centers have been the fastest growing product line in Hurco for the past 5 years, since we introduced our first 5-axis machine 16 years ago.   The adoption rate of 5-axis technology has increased significantly over the years as end-users have gradually learn of the benefits and requirements of 5-axis technology through an industry wide push by machine tool and control builders, CAM software, cutting tools and accessories suppliers.  The shortening product life cycles and the dynamic economic environment have also resulted in an increase application of 5-axis machining for R&D, prototyping and batch production.

We believe that 5-axis machining centers will remain a core part of the Hurco machine offering and we will continue to expand our product range to include larger and faster 5-axis machines.  The recently launched VCX600i Cantilever style 5-axis machining center features key enhancements such as a high-speed motorised spindle, direct torque tables, absolute encoders and fast cutting feed rates.

IMNA: You mentioned 3D Solid Model Import last time. Based from reports it was a huge success in IMTS 2018, have you introduced this here in South East Asia? Please describe the functions briefly and what the benefits are.

Wai Yip: We have officially launched the 3D Solid Model Import in SEA and will organise a series of workshops in various markets to promote its features and benefits.  The take-up rate for 3D solid model import software for new Hurco machines has been overwhelming (close to 50% for a key market like Germany) which is a good indication of its popularity.  The 3D solid model import essentially allows a machinist to create a Hurco conversational program on our Winmax Control with a “few clicks” on the 3D STEP model.  The profile of the part is automatically captured without having to program each line, contour or hole position.  For 5-sided machining, the transform plane feature has been simplified to a few clicks on the 3D model to define and move the part reference and transform the original work plane to the next work plane.  This means that the end-user will be able to reduce their programming time further with a 3D STEP file input and navigate multiple-side programming with ease without the hassle of understanding the complex G codes.

IMNA: Speaking of 4.0, what are some of the biggest challenges of Industry 4.0 for you as a machine tool manufacturer? Some people would rather stick with “established” forms of production, for instance, those who simply do not want to introduce fully automated manufacturing and smart factories? Would you try to push them to go with the flow?

Wai Yip: The biggest challenge in my opinion is to align and prepare our team to meet the needs and demands of automation and smart manufacturing.  More importantly, we aim to assist our customers (especially from the Small & Medium Enterprise segment) to bridge their knowledge gap towards automation.  A small job shop could take the first step towards automation by adding a collaborative robot to their existing Hurco machine(s) and utilise the in-built Hurco Job List software to schedule their programs for machining, with minimal investment.  This could help to remove their psychological barrier that automation is a lengthy (somewhat painful) process that involves substantial investments in both financial and operational resources, which may be seen as an overkill for their small business.

Business owners and management must embrace technology to solve the prevailing manpower issues such as the lack of skilled workers and escalating costs.  In order to stay competitive, process improvements could be implemented to automate the mundane, recurring tasks so that your best machinist can work on jobs requiring higher skill proficiency or develop new skillsets. The automation process could be scaled upwards at a later stage to incorporate smart manufacturing with integrated production data analytics as company progresses, based on their specific needs.

IMNA: Lastly, what are the company’s initiatives for increasing productivity and efficiency in the shop floor, your future plans and strategies for the South East Asia market?

Wai Yip: Hurco will continue to upgrade our control and software technology to improve the user experience through simplifying the programming process for increasing complicated parts.  Our engineering team has recently created a video: “Alexa meets Hurco” to showcase the power of connectivity and automation that is possible with Hurco machines.  We are actively exploring new and innovative ways to integrate Hurco machines with various automation platforms to future-proof our product development.

Hurco SEA will continue to reach out to our customers and end-users through a series of targeted events, specifically tailored for each market, so that we can offer new machines and software to raise customers’ productivity thereby improving their overall profitability.