machining center
machining center Modular, flexible, productive and efficient The right solution for every application, from small to large series production: at this year’s EMO in Hannover Schwäbische Werkzeugmaschinen GmbH (SW) is presenting two new products. The innovative Sfix system (Smart Fixture) is capable of automatically assembling modular clamping fixtures for workpieces, enabling efficient and precise clamping even for small batch sizes. With the new BF 12-21D machine tool, SW is responding to the current trend in automotive engineering toward die-cast aluminum body parts. In line with this year’s trade fair motto “Innovate Manufacturing” Schwäbische Werkzeugmaschinen GmbH is presenting its response to current trends and requirements in production technology at EMO. “Especially outside the automotive industry we see great potential for optimization in medium- and small-series production, which requires greater flexi - bility and modularity from manufacturers” says Michael Kreuzberger, product manager at SW. “To address this, our new Sfix system revolutionizes clamping technology: through automation it enables higher productivity even in production lines with smaller batch sizes.” Modular and automated clamping The Sfix system offers a solution to one of the biggest time wasters in the clamping of small- to medium-sized product series: while companies with high production volumes typically use dedicated clamping fixtures for each product, this approach is not economically viable for small batch sizes. Storing multiple fixtures over the long-term is often impractical due to space limitations and escalating costs. As a result many manufacturers are forced to manually create a new clamp ing fixture for each new product series. The Sfix system offers a flexible solution to this challenge: it automates the assembly of the appropriate clamping technology for each workpiece – and provides users with a virtually unlimited number of clamping fixture for a one-time investment. At the core of the system is SW’s patented Sfix plate, which features retractable pins that allow for flexible positioning of components. Various clamping modules can then be attached to these pins to build the individually required fixture. The advantages of the Sfix system extend beyond its modular mechanical design: in the so-called S-cell, which SW is presenting at its EMO booth, the clamping fixture is assembled quickly and fully automatically. The cell is equipped with all necessary clamping components and workpiece carriers as well as a robot. Users only need to define the clamping points within the CAD model and configure the fixture setup. The smart, AI-supported system then generates a bill of materials for the required elements and automatically programs the robot for assembly. “The Sfix system eliminates the time-consuming manual preparation of clamping fixtures entirely”, emphasizes Kreuzberger. “Processes that Its hybrid machine design makes the new BF 12-21D machine tool ideal for machining die-cast aluminum car body parts economically previously required several hours are now completed within minutes. In addition the S-cell requires very little floor space, making the storage of existing large fixtures obsolete.” SW will demonstrate the system’s rapid fixture assembly in live presentations at EMO. New machine for current trends At the trade fair SW offers not only solutions for small batch sizes: with the BF 12-21D the company is also presenting a new machine tool for high production volumes. As part of SW’s BF series the system is specifically designed for the fast machining of frame and structural components. “In automotive engineering we are seeing a clear trend toward the use of aluminum die-cast parts in vehicle body construction” explains Kreuzberger. “These parts require less manufacturing precision than, for example, gearbox or stator housings. With the BF 12-21D we offer an economical and dynamic machine concept for precisely these applications.” The BF machine series differs from other SW machines in its structural design: to fit the specific market conditions, it features a hybrid axis configuration, utilizing a linear drive for the X-axis, while the Y- and Z-axes are driven by ball screws. SW also relies on proven twin-spindle technology to easily meet high productivity requirements: with two 3-axis units and one spindle per working area, the BF 12-21D can replace two conventional single-spindle machines – and achieve higher output with a smaller footprint. When components are changed in one working area, the second spindle in the other working area can be used to achieve even higher productivity. Maximum output per footprint For maximum productivity requirements SW is also exhibiting a proven machining center at EMO: The BA 442 is one of SW’s fastest and most sustainable machines. With four spindles it offers maximum effectiveness per space while also being energy-efficient. Compared to four single-spindle machines, users can save around half the energy required with 42 no. 3, September 2025
machining center the BA 442 and need significantly less floor space. SW’s patented monoblock design ensures high machine rigidity and correspondingly high accuracy. The tool magazine is one of the largest in the entire SW portfolio, with up to 232 tools. At EMO the BA 442 will demonstrate its capabilities through two distinct applications: while one side of the table will machine a hydraulic valve, the other side will showcase free-form surface milling using 5-axis simultaneous machining. “The BA 442 is suitable for all industries where maximum productivity meets high quality standards” emphasizes Kreuzberger. “Our objective at EMO is to showcase solutions for every need. After all, as a system provider we strive to achieve the best results for our customers in every application – or as we put it: best per part.” EMO 2025, hall 12, booth C05 With the new Sfix system and S-cell, SW offers a new solution for modular and automated clamping technology A world first at automatica: mobile robot cell Schwäbische Werkzeugmaschinen GmbH (SW) presented a new solution for modular automation at automatica 2025: the Mobile i-Cell robot cell, which is a scalable unit that flexibly connects assembly, logistics and machining stations. It supports manufacturing companies in the automated and efficient machining of a wide variety of components and order volumes – without rigid interlinking or complex integration. The Mobile i-Cell, a mobile robot cell takes over automated processes such as handling workpieces and operating machining, washing or assembly stations, thereby replacing manual processes in production. “As a mobile unit for automated machining, the Mobile i-Cell opens up new possibilities – from small-scale to easily expandable large-scale automation” says Roman Wolf, team leader for control technology development at SW Automation. With its combination of high productivity, modular design, flexible application options and end-to-end connectivity, the self-sufficient Mobile i-Cell fits seamlessly into modern manufacturing environments – especially where product diversity and dynamic production requirements are commonplace. Flexible positioning, targeted automation The i-Cell is mounted on a mobile carrier system and can be moved through the production environment using a driverless transport system (Mobile i-Wagon). The cell docks at the desired station, be it machining, washing, assembly or a DMC laser station. An integrated robot with a gripping system takes the raw material from upstream storage stations, known as Mobile i-Storages, loads the machining station, and returns the workpieces after completing the process. The Mobile i-Storages are also automatically movable by the Mobile i-Wagon, and the workpieces are fed and removed independently of the cell. “The flexible docking eliminates the need for complex and rigid coupling of the processing stations with the robot cells – and our customers gain effi ciency and design freedom” says Roman Wolf. This saves space, increases machine availability, and makes production processes more adaptable. The system automatically recognizes the respective station type and adapts processes – without time-consuming manual changeovers or recommissioning. The Mobile i-Cell presented at automatica is designed for payloads of up to 120 kg. The cell can be flexibly networked with SW machines or with systems from other manu fac turers. Power supply and control are handled directly by the respective station or via SW’s own automation platform, which orchestrates robots, transport systems, and order data. Another advantage is that the cell only docks at a station temporarily, keeping the station freely accessible at all other times – for cleaning, maintenance or similar tasks. This keeps the system highly available and easy to integrate. Modular production concept for greater flexibility and scalability The strengths of the concept lies in its modularity and mobility. Companies can start with just a few modules and expand the system step by step as required – a clear advantage over fixed production lines. “Meaning that investments remain predictable and can be adapted to changing requirements” emphasizes Wolf. The Mobile i-Cell demonstrates its advantages particularly when component types and quantities change frequently, such as in the automotive industry with engine blocks, oil pans or bushings. By using several cells in parallel the system runs consistently at high capacity, even with short cycle times of less than 10 min. Companies also benefit from the modular concept: they can start with just a few units and expand the system flexibly as needed. The Mobile i-Cell is patent-pending and was demonstrated live for the first time at automatica in conjunction with an AGV. The robotics and AMRs used were provided by system partner KUKA. further information: www.sw-machines.com no. 3, September 2025 43
