Thermoform tooling is all about surface finish. Thin sheets of heated plastic draw immediate attention to any surface imperfections after the molding process.
Thermoform tooling made by O'Neill Components starts with a 20" x 30" x 4" block of aluminum and is cut for up to 80 hours into complicated 3D shapes. The molds are then used in factories (to produce plastic trays for packaging) and bakeries (molding confectionary items). Thermoformed plastics are preferred over wood or glass for food packaging since these plastics are lightweight, flexible, bacteria-resistant, odor-free and moisture resistant.
As O'Neill Components' orders for thermoform molds began to exceed their capabilities, owner John O'Neill began looking for a new VMC to add to his shop. "I chose the KAAST VF-Mill for several reasons," O'Neill explained. "We prefer the FANUC control, which has proven to be very reliable in harsh conditions. Also, most machines in this class have 20 in. Y-axis travels. The VF-Mill 1100 has a Y-axis travel of more than 21 in. That extra inch can make the difference in taking on that extra job. And, it has a compact overall footprint."
The way a CNC VMC is built affects the way it performs. "With premium-quality components, high accuracy and attractive price points, KAAST is setting the standards for how to build VMCs," said a company spokesperson.
Featuring an advanced design with reinforced body structure through FEM analysis, VF series offers enhanced cutting performance and reduced vibration to meet the highest machining requirements. Extra wide machine column and base design offer high rigidity during high-speed machining.
KAAST VF Series machining centers offer options for customers to prioritize performance, rigidity and/or speed. This 3-axis (4/5th axis available) machining center features tempered stress relieved cast-iron frame and class C3 ballscrews for accuracy and durability. All models include a fully enclosed splash guard, 24 pocket tool changer, 10,000 RPM spindle (12,000 RPM and 15,000 RPM available), and an automatic lubrication system, as well as other features.
Running the newest generation of the FANUC Series 0i control systems, the VF Series machining centers can receive programming manually or via USB, CF card or ethernet.
"The VF-Mill 1100 has performed great for us," said O'Neill. "I even ran it over the hot summer in a room with no A/C, with no issues." Most of O'Neill's projects on the VF-Mill run 60-80 hours continuously. The machine hums along with little to no human intervention needed once the program has begun.
The best indicator of a quality machine for thermoform tooling production purposes is surface finish while running at high speed. "We are able to push the VF-Mill a little faster and still get better surface finishes. Our surface finishes are excellent and have reduced hand polishing, decreasing our overall production time," said O'Neill. "We do not break as many small end mills (.012 in. to .016 in. diameter) as we have in other machines."
O'Neill Components also performs many hours of engraving at high RPM on the VF-Mill 1100, and the spindle chiller option included on this machine has kept the repeatability accuracy to +/- 0.004 mm (+/- 0.00015"). "I am very happy overall. Our sales tech worked with me during purchasing and had a chiller control board expedited to me to replace a board that was damaged in shipping/rigging. I have had zero down time since then. No air leaks, no fluid leaks. Our plan for the future is to invest in more KAAST equipment as we grow," O'Neill concluded.
The VF-Mill 1100 is just one model of the VF family available from KAAST. For training, too room workshops, R&D and model making, the VF-Mini features a 12-position umbrella tool changer to go with the 10,000 RPM BT40 spindle. Offering 19.7"/11.8"/15.75" travels for the XYZ axis and a 25.5" x 12" table that can hold up to 440 lbs., the Mini also features ±0.0004/12" positioning accuracy and ±0.0002" repeatability accuracy. A footprint of only 65" x 94" squeezes this machine into the corner in almost shop.
Authored by KAAST Machine Tools
For more information contact:
KAAST Machine Tools, Inc.
3 Merion Terrace
Aldan, PA 19018
610-441-7317
www.kaast-usa.com