IMTS 2024

IMTS 2024 is a wrap and what a show it was. Featuring 1,737 exhibitors, more than 40 million pounds of machinery, 1,226,523ft² of show space, and 89,020 registrants, attendees and exhibitors weren’t disappointed.

The common theme one noticed throughout the show was solutions to help manufacturers increase productivity and reduce costs – from new machine tools to automation, software, machine learning, and digital advancements. And education was a big draw as the IMTS 2024 Conference, which is powered by AMT – The Association For Manufacturing Technology and managed by GIE Media’s Manufacturing Group, attracted 53% more registrants than in 2022 across the 69 sessions.

According to Peter R. Eelman, chief experience officer, AMT, which owns and produces the show, “IMTS 2024 will accelerate the adoption of advanced technology in ways visitors could not have imagined before the show. A sense of new possibilities generated an enthusiasm felt throughout the show.”

Regarding how exhibitors stood out this year, Douglas K. Woods, president of AMT, says: “Exhibitors fine-tuned their demonstrations, packaging their solutions in the way people want to consume it. Rather than featuring a product, exhibitors showed how they solved problems with systems. That’s the genius that excited visitors.”

Following are some highlights of new products unveiled across the four halls.

Renishaw

Showcased in the East Hall was the RMP24-micro, the smallest wireless machine tool probe on the market, measuring just 24mm in diameter and 31.4mm in length. It delivers market-leading metrology performance with measurement repeatability of 0.35µm 2σ and low trigger forces.

RMP24-micro uses Renishaw’s updated radio transmission protocol to communicate with the machine tool controller – via the RMI-QE radio interface. With an operating range of up to 5m, it employs a 2.4GHz frequency hopping spread spectrum (FHSS) protocol, which is industry-proven and compliant with radio regulations worldwide. FHSS technology enables the probe and interface to jump from channel-to-channel while maintaining communication, allowing the probing system to operate alongside other radio sources such as Wi-Fi, Bluetooth, and microwaves.

INDEX

Front and center at the INDEX booth was the C200 FANUC which incorporates the INDEX SingleSlide guide system and three turrets to maximize the number of tools simultaneously in the cut. The INDEX SingleSlide system provides two degrees of movement in one plane. The system is composed of guide strips with wear- and friction-reduced coating and hardened and surface-treated guide plates. SingleSlide allows for high dynamic response while providing strong damping performance, resulting in lower cycle times, tool life increases of up to 30%, and excellent part quality.

The C200 FANUC incorporates three VDI25 turrets accommodating 14 tools each. Applying all three turrets simultaneously allows for dramatically reduced cycle times. Operators can apply two Y-axes to the main spindle or one Y-axis on the main and counter spindles to further optimize production of complex parts.

OPEN MIND Technologies USA

The hyperMILL 2024 CAD/CAM software suite includes a range of enhancements to its core toolpath capabilities, as well as new functionality for increased NC programming efficiency.

A new, novel generation of programming assistance and analysis, CAM Plan, is introduced in hyperMILL 2024, simplifying various programming tasks and identifying possible sources of error. Predefined workflow steps safely guide users through the preparation and programming process, while the geometries and features required are automatically created. Also, potential errors are flagged for removal such as double surfaces or gaps between model patches.

Once the data is organized, the CAM workflow can be processed with more intelligence and higher efficiency. The first benefit from hyperMILL CAM Plan is component topology is analyzed to produce a precise toolpath with command locations aligned with key geometric features and with optimized point distribution for milling. The result is improved surface finishes, easier processing by NC controllers, and reduced machining times.

Chiron

The Micro5 is what the company calls the “must-have in micro-machining.” With a footprint of 10.76ft2 and energy consumption of 0.5kW the Micro5 machines ultra-precisely complex and high-quality parts for medical devices, watchmaking, jewelry, and highly specialized tiny components. Automated with the Feed5 automation system, the modular design of Micro5 can grow step by step from prototyping to large-scale production, delivering high autonomy.

Mastercam

The latest version of the company’s software – Mastercam 2025 – offers features and enhancements to maximize speed, efficiency, and precision in machining operations.

One new feature is Mastercam Deburr, an advanced solution for automated edge finishing revolutionizing the deburring process for Mastercam Mill, Mastercam Mill 3D, Mastercam Router, and Mastercam Mill-Turn. Mastercam Deburr allows users to leverage the streamlined deburr cycle in a 3-axis environment without requiring Mastercam Multiaxis. For users with Mastercam Multiaxis, the familiar simplified controls ensure an easy transition.

Mastercam 2025 also introduces Finish Passes to 2D Dynamic Mill and Area Mill toolpaths. The Finish Passes page allows users to add high-speed finishing passes along the selected toolpath boundaries, with configurable parameters for feed rate and spindle speed overrides, ensuring a smooth and precise finish.

CERATIZIT

Featured at the company’s booth in the West Hall, CERATIZIT showed its OptiLine Series of solid-carbide end mills with the launch of a 6-flute end mill. OptiLine end mills are versatile and optimized for various materials, machining strategies, and part applications. The company designed and developed the new six-flute OptiLine end mill specifically for titanium and super alloys (ISO-S).

Engineered from the ground up, the OptiLine 6-flute end mill features a premium substrate and advanced tool geometry. The end mill’s asymmetrical variable helix and variable index flute configuration ensures enhanced stability during cutting operations and includes chip splitters designed for applications involving 2.5xD cutting lengths. Refined cutting edges and CERATIZIT’s Dragonskin coating technology improve chip control and reduce adhesion for longer tool life.

Mazak

While the Mazak booth was jam packed with machines and people, one highlight was its new VARIAXIS i-600 NEO vertical machining center (VMC) in the company’s Advanced Machining Action Area. The VARIAXIS i-600 NEO is the next generation of Mazak’s full 5-axis VARIAXIS i-600 VMC easily machining multiple and complex curved surfaces on small and medium-sized workpieces in single setups for shorter production cycle times.

On the control side, the VARIAXIS i-600 NEO is equipped with Mazak’s MAZATROL SmoothAi CNC. For fully optimized machining operations, the artificial intelligence (AI)-powered technologies within the MAZATROL SmoothAi control make for fast and easy programming, controlled spindle speed for reduced vibration, and greater machine thermal stability.

Sodick

Highlighting several electrical discharge machining (EDM) and milling machine tools, the company also spotlighted its increased focus on automation. New products included the UX650L high-speed vertical machining center, which combines rough and fine milling in one operating mode, offering stability and precision.

Also featured were the ALN800G IGE+ and AL400P IGE+ wire EDM machine tools, equipped with Sodick’s iGroove+ technology reducing wire consumption up to 39%. The AL40G+ Sinker EDM showcased several automated and robotic features, highlighting an industry-wide move toward greater automation.

Kyocera SGS Precision Tools Group

The cutting tool company showcased several industry-spanning parts manufactured and machined using its tooling, from high-precision circuit boards and medical implants to aerospace and automotive components.

New for 2024 was the Z-Carb XPR high performance end mill line. The cutters feature augmented ramping and plunging capabilities, enabling more aggressive tool paths and a wider range of roughing and finishing techniques.

Hurco

Hurco demonstrated the capabilities of ProCobots automation on several Hurco machines. Attendees saw how simple it is to set up and run different jobs through the Hurco control’s Automation Job Manager feature, which eliminates the need for robot programming. Attendees also learned how quickly ProCobots can be moved from machine to machine.

While there was a heavy focus on automation, the Hurco control is what makes such complete automation integration possible. Attendees were able to interact with demo consoles and see the demonstrations on the following Hurco models: the new TM8MYi with live tooling and a Y-axis and the TM8i slant-bed lathe; the 3-axisVM ONE, VM15Di, VMX42Di, and the 5-axis VMX60SRTi and VC500i.

HAIMER

The company’s booth was set up to include a 6,000ft2 Tool Room of the Future displaying a range of tools, tool holders, and the WinTool Data Hub. Other new products included the HAIMER Hybrid Chuck, which combines the properties of hydraulic and shrink chucks.

The Automation Cube One officially debuted at EMO Hannover in 2023 but made its U.S. appearance at IMTS 2024. Further continuing the show’s automation trend, the fully automatic robotic cell can shrink, unshrink, and measure tools and offers up to 11 axes for part handling. The Automation Cube One has been recently equipped with measurement technology and sensors.

Galorath

SEERai platform is a chatbot-based generative artificial intelligence (AI) system designed to help digital engineering professionals plan and estimate projects. SEERai evolved from Galorath’s SEER cost, schedule, and risk estimation platform and is trained with data and methodologies the company gathered and developed throughout four decades. SEERai is designed to continually evolve through user feedback and new data incorporation, allowing it to anticipate future project needs.

DN Solutions

Another highlight in the South Hall was the DVF 5000 Second Generation machine for seamless machining of complex shapes and curved surfaces in a single setup. The DVF 5000 Second Generation boasts significantly faster X-, Y-, and Z-axis feed rates doubling the speed of its predecessor. Additionally, it showcases a 25% increase in B- and C-axis rotation speed, now at 25rpm, alongside a tool-to-tool time of 1.3 seconds and a chip-to-chip time of 3.8 seconds.

The DVF 5000 Second Generation presents expanded machining capabilities, providing greater flexibility with enlarged workpiece and clamping tool sizes. Featuring a table size of 630mm x 450mm (24.8" x 17.7") and accommodating a maximum workpiece size of 600mm x 500mm (23.6" x 19.7"), it boasts a 26% increase in table size and a 32% expansion in maximum machining area.

About the authors: Elizabeth Engler Modic is editorial director and Clare Scott is associate editor of GIE Media’s Manufacturing Group of magazines. They can be reached at EModic@gie.net and CScott@gie.net.