(NUM: Teufen, Switzerland) -- Star Cutter, a global leader in cutting tool technology, has launched its revolutionary FLX machine. Powered by NUM’s advanced FlexiumPro CNC control system in combination with NUMROTO software, it easily programs all kind of different tools. This significant advancement underscores Star Cutter’s commitment to delivering cutting-edge solutions for high-volume tool manufacturers, providing an enhanced platform for automated, high-precision manufacturing.
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A ground-up redesign and technological leap
The decision to transition to NUM’s FlexiumPro CNC control system was driven by Star Cutter’s dedication to innovation and operational efficiency. The FLX machine represents a complete redesign from previous models, making this the ideal moment to adopt NUM’s latest FlexiumPro CNC system along with NUM DrivePro servo amplifiers.
“Leveraging the strengths of previous Star machines, the FLX was a ground-up machine redesign,” says Brad Cooper, plant manager from Star Cutter. “It was the right time to migrate to NUM’s FlexiumPro system, ensuring seamless software transitions and significant improvements in automation, power consumption, and data security.”
Key features of the NUM FlexiumPro CNC system
One of the standout features of the new FlexiumPro system is its seamless integration with existing technologies. Star Cutter reused much of the logic and custom programming developed for earlier generations of NUM systems, significantly reducing engineering effort during the transition.
Among the FlexiumPro’s innovations is a modernized EtherCAT communication interface that reduces power consumption and shrinks the electrical panel footprint. The system’s cutting-edge, single-cable motors allow for easier maintenance, while its system-on-chip (SoC) technology has increased CNC computing power tenfold. The FLX machine’s B and C axes are driven by NUM’s TMX series hollow-shaft torque motors, ideal for tool grinding applications, which demand smooth and accurate rotation, especially at low speeds.
“The system architecture also supports NUM’s high-performance single-cable motors, making maintenance easier and allowing us to take full advantage of modern connection systems,” says Cooper. “The maintenance of this machine type has never been easier, and the performance enhancements ensure it is ready for lights-out manufacturing.”
Performance and efficiency gains
The FLX machine is designed with automation and wheel change enhancements, making it ideal for high-volume toolmaking customers. One of the most notable improvements is a 30% reduction in wheel change time, thanks to a redesigned wheel magazine area and increased system processing power.
Star Cutter has also integrated robotics to handle both wheel and tool changes, offering up to 15 wheel pack locations and 1,200 tools, which significantly extends automated production runs. This makes the FLX a game-changer for catalog-standard carbide tooling manufacturers.
In terms of efficiency, the FlexiumPro system’s built-in IIoT (industrial internet of things) connections facilitate seamless transmission of production statistics to plant analytics systems. The inclusion of supercapacitors in the system’s real-time kernel ensures safe shutdowns during power failures, further enhancing the reliability needed for lights-out manufacturing.
A competitive edge in a demanding market
The introduction of the FLX machine with the FlexiumPro CNC system, plus the NUMROTO software for generating the grinding programs, puts Star Cutter at the fore of the cutting-tool manufacturing industry. The combination of innovative automation, enhanced reliability, and state-of-the-art technology offers a distinct competitive edge.
“As the toolmaking industry continues to evolve toward lights-out production, the reliability and advanced capabilities of this system will play a crucial role in maintaining productivity and efficiency,” says Aaron Remsing Jr., sales manager at Star Cutter. “The NUM FlexiumPro system, combined with the robust FLX platform, enables us to meet the high production demands of our customers like never before.”
Looking ahead
Star Cutter remains focused on advancing its FLX, NXT, and PTG platforms to serve a broader range of industries. Future enhancements will continue to align with customer needs, particularly in the high-production and medical sectors. As part of its commitment to customer service, Star Cutter will ensure a smooth transition for clients adopting the new CNC system, providing comprehensive support and training to ensure optimal performance.
“Our customer service and support will remain our top priority,” says Remsing. “We are dedicated to making the transition to the new CNC system seamless for our customers, ensuring they continue to receive the high level of service they have come to expect from Star Cutter.”
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