Driving ahead with smart sheetmetal processing

Trumpf 4
Trumpf 4

Trumpf has been at the forefront of developing a widespread range of technologies for cutting and forming sheetmetal. Ed Hill visited its UK headquarters in Luton to hear more about its latest advances. 

Trumpf has been at the forefront of developing a widespread range of technologies for cutting and forming sheetmetal. Ed Hill visited its UK headquarters in Luton to hear more about its latest advances.


Trumpf is not a company that rests on its laurels when it comes to developing new manufacturing technology. The German sheetmetal processing specialist regularly updates its product offering of flatbed lasers, punches, welders, bending machines and production cells and in recent years has started expanding into markets such as additive manufacturing and power tools.

At its UK headquarters earlier this year, the company reported on its latest sales figures and showcased a number of new products and services that will help its customers grapple with the challenges of increasing productivity, automation, connectivity and the benefits of that modern manufacturing doctrine, Industry 4.0.

The first of these is the new flagship model of its TruLaser flatbed series; the TruLaser 5030 with a new 10kW fibre laser cutting head. Not only does this machine feature a more powerful laser (beneficial for cutting thicker sheetmetal) it also includes a number of technological advances that mean significant performance and efficiency improvements for users.

Trumpf sales director Gerry Jones comments: “The machines in this series are not just upgrades; they are entirely new platforms. The Trulaser 5030 has higher acceleration and deceleration dynamics of around 20%. It has a new touchscreen control which is quicker to use and we have added a 6m option. This means the 5030 is a large format machine but it is still very agile.”

The Highspeed Eco system means a greater concentration of nitrogen gas is used while the laser is cutting

Eco power


Perhaps the most important innovation is Trumpf’s patented Highspeed Eco technology. Put simply, this optionally available system is made up of a moveable sleeve that encircles the cutting nozzle at the point it makes contact (touchdown) with the surface of the metal, concentrating the laser and significantly reducing the amount of nitrogen used in the cutting process; rather like the skirt on a hovercraft concentrates the flow of air.

Trumpf says this simple device can provide nitrogen savings up 70% and also leads to increased cutting speeds.

“Essentially these machines are about improving productivity,” Mr Jones continues: “If we look at sheet throughput – which includes the whole process not just speed of cut – in the 1 - 3mm thickness range, its improved dynamics improve productivity by 5% whether it’s an 8kW or 10kW laser.

“However, when we go to 4 - 12mm thickness we see a 20% increase in sheet throughput with a 10kW machine. At 12mm (heavy plate) it’s a 10% increase in throughput when a 10kW laser is combined with our Brightline fibre technology.

Cutting with Trumpf’s Active Speed Control

He adds: “With Highspeed Eco, a lot of our customers favour nitrogen gas cutting rather than oxygen as it results in faster speeds generally – however this means a high consumption of nitrogen, which is costly.

“Highspeed Eco means less nitrogen gas escapes; effectively forcing it into the kerf. It means our machines can operate at much lower gas pressure. Other benefits of this patented Trumpf technology mean being able to cut mild steel faster and thicker and in some cases an increase in sheet throughput by as much as 100%.”

A new development for Trumpf that is also available as an option on the TruLaser 5030 is Active Speed Control, described by Mr Jones as bringing, “self-intelligence onto our lasers”.

Active Speed Control has a camera system that looks directly through the nozzle right at the cutting zone. It constantly monitors the kerf and resulting molten metal, autonomously controlling the feed rate of the solid-state laser and adjusting for minor fluctuations in the material’s thickness or sheet surface contaminations such as rust or paint.

This means the laser is constantly operating at the optimised feed rate rather than relying on fixed parameters set by an operator. Not only does this reduce the risk of scrapped parts by reducing burr and slag formation and other errors, it also frees operators to carry out other tasks while the machine is operating.

Significantly in an era where Trumpf is also promoting more automation, it means machines can be left more easily to operate unmanned.

Cutting without Active Speed Control

Lee Moakes, Trumpf’s UK managing director comments: “This has not been available on any of our other laser cutters in the UK before. It is constantly self-regulating meaning the cutting process is more secure and whatever the quality of the material being cut you will always get a good part.

“It also adds to the degree of automation because machine operators are often employed to do more than just monitoring a machine. If this system is linked to an automatic loader you can see the potential benefits as it can be set up for long running intervals without the need for an operator. Intelligent systems that can react to these circumstances mean a much greater reduction in scrap.”

Bending better


When it comes to bending metal, Trumpf promoted its latest TruBend 7000 series machines. Like their laser counterparts these electric driven press brakes, intended for small to medium sized parts, have new touchscreen controls. These can be flexibly moved by the operator to suit their particular requirements while carrying out a bending operation.

Arguably, the biggest enhancement of these machines is not the mechanics but the addition of Trumpf’s TecZone Bend software which dramatically reduces the time creating a bending sequence program.

TecZone Bend is a fast and simple program meaning users can either program a bending process at the machine or offline in the office. It can also transfer the files back and forth seamlessly between the two. On the basis of 2D and 3D data models, the software automatically creates NC programs. It means that within seconds a bending programme can be calculated, including collision checks, dismantling of assemblies, management of set-up plans and more. Also, by prioritising the tools (dies) being used it reduces the work required and increases production.

Lastly, on the new product front, Trumpf with its expertise in lasers has been working hard on developing its additive technology. It now offers three ranges of machines: the compact TruPrint 1000 (100 by 100mm build volume) intended for parts such as those found in dental, medical and jewellery; the TruPrint 3000 for larger volume parts (300 by 400mm) and the TruPrint 5000 machine with the same build volume but intended for higher serial production.

Mr Jones explains: “3D printing is an increasingly important market for us. The TruPrint 5000 has a lot more interconnectivity, smart advances and self-analysing technology meaning it can log how a part has been made.

“It also has three lasers that can all work on a part at the same time – i.e. build layers simultaneously. We have also made it a much more interconnected and software orientated machine because a lot of additive work is done by managing 3D models over the Internet. We believe it is well-ahead of the competition in terms of Industry 4.0 and connectivity.”

Active Speed Control constantly monitors and adjusts the cutting zone using a camera sensor

Sales success


Mr Moakes reported that Trumpf’s UK sales performance had exceeded expectations in the last year, achieving orders of £55 million for 2017-18 despite factors such as Brexit, and it was well on target to beat those in 2019. He also said the company would continue its digital transformation, particularly through the improved ‘Smart Services’ support it now offered its customers.

“We have had a very strong increase in laser orders and our bending machines have also seen a considerable rise,” he affirms. “With our lasers there has been a move from customers to acquire our higher range 5000 and 7000 series machines and also for large 5-axis systems.

“Our vision is to be the most highly regarded metalworking solution provider in the UK. Our focus is to enable our customers to grow their own businesses because their success is our success. This means we have a duty to continuously improve and adapt ourselves and our solutions to enable our customers’ own growth ambitions.”

Trumpf www.trumpf.com/en_GB/

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Trumpf

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