FlexiCAM » Applications » Railways


Processing of large scale aluminum and composite sheets

The use of tough, weldable, formable, and corrosion-resistant aluminum alloys has made them the material class of choice for weight sensitive train, tram and metro applications with a high recycle value.

By using aluminum and composite materials manufacturers can design with high-speed capability, high payloads, long life, and low maintenance costs.

With FlexiCAM’shigh performance chip extraction system that allows recycling of aluminum chips, and the Nested Base Manufacturing (NBM) of aluminum parts, you can expect less waste and increased productivity.

The excellent edge finish and extremely tight tolerances of the cut no longer require secondary processing of the parts thus the parts and edges are ready for bending, welding, etc.

Pocketing, grooving, drilling and tapping of parts as well asmilling off welds are likewise possible within machining operation, as well as printing part numbers, aligning marks and folding lines directly onto the parts before cutting.

Manufacturing of Patterns, Molds, Jigs and Prototypes

Large dimension patterns, molds, jigs and prototypes can be produced in high quality from a single workpiece or large sections by using FlexiCAM’s large format 5-axis CNC machining centers.

Trimming, Drilling and Cutting of Aluminum and Composite Parts.

The machining of aluminum and composite parts for railways, tramways and metros requires consistent quality of finished parts with tight tolerances.

FlexiCAM offers a wide range of CNC router solutions for the processing of aluminum and composite components as well as complete assemblies for train, tram and metro car bodies, sides and roofs including window and door openings.

These high speed 5-axis CNCs are machining all commonly used materials in the railway industry such as wood, sandwich panels, honeycomb and foam core materials, glass and carbon fiber reinforced polymer (GFRP / CFRP), epoxy, polyester, phenolic,EPS, PU, as well as many other advanced composites.

Trains and Transportation Systems Interior Solutions

FlexiCAM CNC Routers can be used for a wide variety of applications in railway interior such as: manufacturing ceilings, galleys and catering modules, lavatories, partitions, storage units, interior and exterior doors, tables and many more.

Countertops (Solid Surface)

Any highly frequented transport environment is heavily exposed to dirt and moisture, yet must be easily returned to hygienic freshness to be attractive to travelers. Because solid surface materials can be cut, shaped and joined to fit precisely in the compact spaces found on coaches and carriages, leaving no joints where dirt may accumulate, cleaning is straightforward and fast. From restroom surfaces to reception counters, dirt and stains do not penetrate the structure, so they can be very easily removed from the surface which is also renewable if damaged.

FlexiCAM CNC routers are one of the most versatile tools for any solid surface operation having the ability to cut, chamfer, rout, inlay, engrave, v-groove and drill. FlexiCAM CNC routerscan machine a variety of solid surface materials including Corian®, Avonite®, LG Hi Macs®, Wilsonart®, Hanex® and others.

Machining Aluminum Extrusions

FlexiCAM offers 3, 4 and 5 axis solutions for all operations required in machining aluminum extrusions, such as routing, milling, drilling and tapping. Due to the large machine sizes available, all operations can be performed while the extrusion is stationary.

The FlexiCAM Stealth provides exceptional value for the money.

It is engineered with rigid steel construction all throughout, with a single piece base frame and coupled with FlexiCAM’sAdvanced Control System (ACS) or an industry standard Siemens control system. The Stealth is great for a medium to heavy use environment, from woodworking to industrial markets, and everything in between.

The system comes with manual or automatic tool change spindles up to 12 KW, allowing for more flexibility without the need of multiple manual spindles or additional boring unit. The FlexiCAM Stealth’s work table can accommodate all popular sheet sizes and comes in many work areas up to 2 m x 11 m with 200 mm (optional 280 mm) clearance. No matter what industry you are in, the Stealth will cater to your requirements.

It is a machine that fits your market, without the need for another machine for different applications, thereby significantly reducing your costs and enhances investment for other projects.

The FlexiCAM XL is a heavy duty and high-performance work horse with single piece base frame offering many different work areas up to 2.5 m x 11 m. It is designed and tested for shops with high production requirements and is capable of 3- to 5-axis machining using the FlexiCAM Advanced Control System (ACS) or an industry standard Siemens control system. The FlexiCAM XL offers a large range of spindles of up to 25 KW, rotary tool changer, high performance chip extraction system, etc. to address specific application requirements.

It is a great solution for all types of demanding applications such as woodworking, solid surfaces, machining non-ferrous metal, composite sheets and plastic parts. With Z clearance from 200 mm to 400 mm (Z stroke up to 480 mm), the FlexiCAM XL is capable of cutting sheet materials as well as machine larger 3D objects such as molds or plugs.

The FlexiCAM XL has guaranteed efficiency and it can be fitted with almost all options available from FlexiCAM including multiple carriages or gantries, rotary axis, C axis, optical (laser) or mechanical probe systems, inkjet or laser marking and much more.

The Piranha is FlexiCAM’s 5-axis machining center designed for high speed machining of large size work pieces such as manufacturing patterns, molds, jigs and prototypes as well as for trimming large-scale structural components, thermoformed or advanced composite parts in the automotive industry.

It has a work envelope of up to 60 m x 12 m x4 m, powerful spindles of up to 25 KW and is running on the FlexiCAM Advanced Control System (ACS) or an industry standard Siemens or Fanuc control system.

The FlexiCAM Piranha excels at processing large parts where long axis travels, height under the gantry and a long stroke is required.

Efficiency of the machine can be enhanced with further options such as multiple gantries, optical (laser) or mechanical probe, palette changer for the workpieces, dust collection system, and much more.

The FlexiCAM Xtreme is a large format modular design CNC router that has a work area of virtually unlimited length and widths of up to 5 m. This machine is ideally suited for machining large format aluminum and composite panels in markets like recreation vehicles, caravan & mobile homes, truck & trailer manufacturing, isothermal containers as well as boat building or aerospace

The FlexiCAM Xtreme allows large format panel processing, part cutting, production line manufacturing, etc. in 3-, 4- or 5-axis operation. It comes with the FlexiCAM Advanced Control System (ACS) or an industry standard Siemens control system.

With many available options such as multiple carriages or gantries, automatic tool change spindles up to 25 KW with rotary tool changer, high performance chip extraction systems, extended Z clearance and stroke and much more, you will be able to exponentially increase your production.