German subcontractor Ament Plastics has successfully transformed its operations by implementing a DMG MORI CLX 450 TC twin-spindle turn-milling centre. This investment has enabled the company to achieve six-sided complete machining in a single setup, reducing throughput times whilst enhancing quality and production flexibility.
Established in 2005 and located in Wernberg-Köblitz, Ament Plastics specialises in producing complex plastic parts. The 25-strong team serves customers across the automotive, medical, and aerospace industries, with thermosetting plastic components.
The company faced significant operational challenges where traditional methods required at least two machines and repeated reclamping operations, substantially increasing cycle times and compromising dimensional accuracy. This was problematic for their core business of machining thermosetting materials.
Thermosetting plastics present unique machining challenges compared to thermoplastics. The company’s founder and CEO, Klaus Ament, explains: “Whilst thermoplastics produce normal chips, thermosetting plastics generate dust that must be flushed away, creating an aggressive slurry.”
Coolant usage is also restricted. Materials cannot absorb excessive moisture in electrical engineering applications, necessitating dust extraction rather than flood coolant. Additionally, laminated thermosets containing synthetic resins with hard paper, cotton fabric, or epoxy glass fibre layers are highly abrasive, requiring specialised tooling strategies.
Ament Plastics selected the DMG MORI CLX 450 TC on several factors. with the machine’s compact footprint a key focus.
The CLX 450 TC features X, Y, Z travels of 750 by 200mm by 1.1m, providing a work envelope for diverse component geometries. Key technical specifications include twin-spindle configuration with counter spindle, compactMASTER turn-mill tool spindle for complete machining, Breuning IRCO bar loader, integrated finished parts container for unmanned operation and in-process measurement.
Six-sided complete machining in a single setup has eliminated the need for secondary operations and reclamping, dramatically reducing total cycle times. Single-setup machining eliminates cumulative positioning errors associated with multi-setup operations, improving dimensional consistency and tighter tolerances. The bar loader and parts collection system enable unmanned overnight production runs, maximising equipment utilisation.
In-process measurement capabilities, employed particularly during series production, enable continuous quality monitoring reducing subsequent inspection time. The complete machining capability allows Ament Plastics to respond more rapidly to customer requirements.
Production Manager Erik Fleischmann oversees the integration of in-process measurement systems, particularly during series runs. This capability enables continuous quality monitoring without removing components from the working area, significantly reducing inspection overhead whilst maintaining stringent quality standards.
Klaus Ament emphasises the long-term strategic value of the investment: “Despite the attractive working environment with technical plastics, finding skilled machine operators and trainees remains a major challenge. Therefore, complete machining and high process integration will remain important criteria for future machine tool investments.”
This approach aligns with industry trends towards increased automation and process consolidation, positioning Ament Plastics for continued growth in high-value precision manufacturing applications whilst addressing workforce availability challenges through technology advancement.