So much more than just machines

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aerospace

So much more than just machines

Starrag offers everything from complete manufacturing solutions with its own in-house components through to special tools

The high quality of the Starrag machines developed and manufactured in Rorschacherberg, Switzerland, is undisputed. But these machining centres are just one facet of the diverse portfolio. The production solutions available also include other components made by the company. In addition to technology, software and clamping concepts, the carbide tools produced in-house are often vital to success.

The core expertise of Starrag’s headquarters in Rorschacherberg lies in developing and manufacturing high-performance machining centres for use in aircraft and turbine construction. But the company actually has much more to offer. The process knowledge accumulated over many years and through numerous projects, are reflected in the many components developed in-house: from carbide tools to the RCS CAM software for blades, from clamping technology and fixture construction to automation solutions and host computer technologies.

“It is this ‘full package’ that sets us apart from other suppliers,” says Sofian Regaz, Starrag Sales Manager for Aerospace & Turbine Technology. “We don’t see ourselves purely as a machine manufacturer, but as a solution provider for production processes in the aerospace and turbine sector. This ranges from standalone plants to flexible manufacturing systems, which customers can obtain from us as a one-stop shop.”

Gaining a market advantage from tools adapted to the process

Sofian Regaz is primarily responsible for product management and sales of Starrag tools. “Here in Rorschacherberg, we have spent many years developing and grinding carbide milling cutters for aircraft and turbine components made from difficult-to-machine materials such as titanium, Inconel or high-alloy steels.”

Though Starrag does offer a small range of standard tools, more than 90 % of the tools the company sells are custom- made products that are tailored to the specific machining process, i.e. to the component, the machine, the material and other considerations.

“It makes a huge difference whether I adapt my NC program to a catalogue milling cutter or whether I design the tool in terms of cutting edge length, corner radius, flank angle, coating, etc. so that I can deliver the optimum machining process. Our customers enjoy great success with this,” says Sofian Regaz.

“It is this ‘full package’ that sets us apart from other suppliers”

Always available to serve customer needs

As Starrag sells most of its machines as part of a manufacturing solution for a specific component or component family, the corresponding specialist tools are usually supplied with them – together with an explanation of why the tools are designed in this way and the expertise on which they are based. The product manager adds: “The customer needs to know how their tools differ from catalogue tools and the impact these differences have. They also need to understand that the advantages of our tools cannot be found with other suppliers.”

This expertise is no coincidence. Starrag maintains a very close, partnership-based relationship with its customers and supports them throughout the entire production process – and even beyond the warranty period. “This means that if, for example, a component is due to be changed and the machine needs to be set up for a new process, we are still by our customer’s side to offer new customised tools as necessary,” assures Regaz. Machine manufacturer Starrag has a clear advantage over traditional tool manufacturers: Tools are both developed and ground at the Rorschacherberg plant, where the Aerospace and Turbine Competence Centre (ATCC) is also located. With 2,000 m2, the centre is fitted with all current five-axis machining centres from the Starrag NB, LX and STC series. Sofian Regaz explains: “We use these machines for a wide range of our own trials and trials for our customers, as well as for developing and optimising processes and, of course, for our analyses and tool tests. We even take on small series production on behalf of customers.”

For the tool team, this means that they can reproduce the customer’s processes 1:1 on original machines and optimise the tools before they are even delivered. Time and again, customers confirm that this saves many transport routes and, in turn, a lot of time and money. “If, however, corrections to the tool are still necessary, we can react and adopt changes very quickly because we have our own grinding shop,” reasons Sofian Regaz. “We achieve incredibly quick response times, sometimes just in half a day.”

Sofian Regaz, Starrag Sales Manager Aerospace & Turbine Technology

“ We achieve incredibly quick response times, sometimes just in half a day.”

Tool expertise for better machining results

The ATCC is an important meeting place. This is where Starrag technologists, machine operators, automation specialists, tool specialists and customers come together. This is because Starrag offers them comprehensive support in programming the machines, running in the processes and also in subsequent process optimisation.

For the tool team, this is a valuable source of expertise. “This is where we find out how the market is evolving, how materials are changing, what the blanks of the future will look like and what requirements components in the future will have to meet. This allows us to get ahead of the game with our tool developments and offer our customers solutions early on.”

Starrag is also well positioned worldwide in tool servicing. In order to save customers time and money, the Swiss company has entered into a partnership with the global company Oerlikon Balzers, who provide on-site regrinding and recoating services for Starrag in America and Asia. This is an important factor for Sofian Regaz. “We do offer a similar service in-house as well, but customers can save themselves the long journeys from overseas by making use of our partner offer.”

“Customer feedback on our tools is consistently positive,” mentions Sofian Regaz. He received a special confirmation of success from Honeywell Aerospace Ireland, where Starrag had the chance to work as a tool problem solver. Starting basis: Tool wear was very high when machining a titanium turbine blade. No more than ten components could be machined with the milling cutter they were originally using. That’s when the engine manufacturer invited important tool manufacturers to get a handle on the problem. The best supplier managed to increase the service life to 20 components. And Starrag? “Our special tools produce 40 components,” reports Sofian Regaz. “Honeywell considered this worthy of not only a contract, but also an award. In June 2024, we were awarded the ’Kaizen of the Month’ prize.”

Success leads to growth

The tool business has seen tremendous growth in recent years. This is not solely down to success stories such as the Honeywell contract. The expanded product range has also contributed greatly to this. While Starrag used to produce only end mills, torus mills and conical ball nose mills, today the company also grinds cylindrical and barrel ball nose mills, lollipop, barrel and chamfer milling cutters as well as high-feed, plunge and a wide variety of form milling cutters, for example for turbine blade roots. In order to generate further growth, Starrag will in the future, offer special tools for machining aluminium in addition to tools for materials that are more challenging to machine. Sofian Regaz’s team is also 21 strengthening its business development: “Our process expertise in aircraft and turbine construction is so extensive that we can also enjoy great success with our tools on third-party machines. And we are already in talks with other Starrag sites. In the future, we want to utilise their machining centres and their expertise to produce special tools for other industries.”