micromechanics

Exakt Fijnmechanika from the Netherlands focuses on complex precision mechanical long turning work with Tornos

No fewer than eight Tornos long-turning machines are currently operating nonstop at Exakt Fijnmechanika in Drachten. The facility, which resembles a clean room, is fully dedicated to the stable production of high-precision turned parts for the medical industry and other sectors.

In 2010, Exakt Fijnmechanika acquired its very first long-turning machine, a Tornos Micro 7, to produce 500,000 cannulas each year for ophthalmology. This product is a hollow tube – similar in size to a needle – used in eye surgery to penetrate the eye and remove fluid or treat certain conditions.

“These types of products must meet the highest standards in terms of dimensions and surface finish. A defect in such a product can result in irreparable damage. That is why we set very high standards for our machinery, and since 2010, Tornos has consistently proven that it can more than meet these requirements,” Exakt Fijnmechanika Director Arnold Douma said enthusiastically.

“These types of products must meet the highest standards in terms of dimensions and surface finish.”

Arnold Douma, Director Exakt Fijnmechanika

Swiss quality

The reason Exakt Fijnmechanika chose Tornos has everything to do with the quality and accuracy of the machines. In long turning, it is essential that the process runs stably to ensure high precision and repeatability. “At the time, Tornos was one of the few machine builders that could meet our requirements. The Micro 7 was perfect for our starting material with a diameter of 0.16 in. (4 mm) and was developed in collaboration with leaders in the watchmaking industry,” Douma explained. “Given the similar demands for precision manufacturing, we were simply charmed by Swiss precision, making Tornos the logical choice.”


Pushing the boundaries

Today, Exakt Fijnmechanika still produces cannulas in large quantities, but other long-turning projects have been added over the past decade. For the medical industry, the company also manufacture small parts for insulin pumps and sharp needles with a radius of less than 5 micrometers. For the defense industry, Exakt Fijnmechanika produces components with very low Rz values used in night vision goggles. “These are just a few examples,” said Douma, showcasing a wide range of precision mechanical turned parts. “We specialize in high-tech turning. When you are pushing the boundaries of what is feasible, you have to be willing to make mistakes. That’s the only way to progress.”

Eight Tornos long-turning machines

Due to increasing demand and positive experiences with both Tornos and Gibas – Tornos’ official distributor in the Netherlands – Exakt Fijnmechanika added a SwissNano 4 to its equipment lineup in 2015. This model succeeded the Micro 7 and features improved user-friendliness in terms of both control and accessibility to the machining space.

“We program directly on the machine to maintain optimal control over the process. With the SwissNano 4, this has become much easier due to the user-friendly interface. Another great feature is the construction of the machine. The glass dome, which can be fully opened, provides complete access to the machining area. Despite the 14-year difference between the Micro 7 and the newer models, the performance, accuracy, and cycle time remain very consistent. That is a testament to Tornos' quality,” Douma noted.

Leaving nothing to chance

Between 2015 and today, six additional SwissNano 4 long-turning machines have been added to Exakt Fijnmechanika’s workshop, bringing the total to eight. All machines have a maximum bar capacity of 0.16 in. (4 mm), which is also the diameter of most starting materials. However, Exakt Fijnmechanika also processes smaller diameters down to 0.04 in. (1 mm). The compact long-turning machines have six linear axes, two C axes, and 13 tools, four of which are driven. Each machine is equipped with a high-frequency spindle capable of speeds up to 16,000 rpm on both the main and subspindles. “We sometimes drill holes of just 0.008 in. (0.2 mm) in diameter. In such cases, 16,000 rpm isn’t enough, so it takes a bit of magic to successfully complete these types of operations,” Douma explained. “Everything has to be perfect, from the alignment of the machine to the quality of the cutting oil, temperature control, and tooling – especially for unmanned production.”

Reliable and unmanned production

Because Exakt Fijnmechanika produces large series ranging from 1,000 to a million pieces, all Tornos long-turning machines are equipped with LNS Tryton bar feeders. According to Douma, this bar loader is ideal for automated production of small-diameter workpieces. “Even with small diameters, there are no vibrations, which allows us to produce all night long with process reliability,” he said.

While Tornos machines are known for their thermal stability, Exakt Fijnmechanika leaves nothing to chance. Seven employees dedicated solely to quality control are proof of that commitment. To ensure maximum process reliability, all long-turning machines are housed in a temperature-controlled room. “At a constant temperature, there’s no need for compensation, which greatly enhances process stability,” Douma said. Furthermore, Gibas has equipped several machines with a paper belt filter to maintain optimal cutting oil quality, preventing small chips from damaging the tool or workpiece. “All in all, we are extremely satisfied with Tornos’ long-turning machines and the support from Gibas. We still have some space available in our long turning department, and we will undoubtedly fill it with more Tornos machines,” Douma said.

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