Whether in medical technology, precision engineering, electronics or optics: the highly dynamic micro-machining of precision components, with short cycle times and tolerances in the micrometre range, is becoming increasingly important. This requires stable processes, a high degree of flexibility and cost-effective production – even where space is limited and the need for automation is growing.
With the Micro5 XL, the CHIRON Group has consistently extended the successful Micro5 concept to cover a wider range of applications: as a platform for high-productivity 5-axis simultaneous machining of complex small precision parts – and as a scalable production solution with integrated automation.
More possibilities for industrial micromachining
The XL stands for greater travel, higher cutting performance and maximum flexibility in 5-axis simultaneous high-speed machining. A key feature is the exceptional 5:1 ratio between the machine’s structural dimensions and the maximum workpiece size – in the case of the Micro5 XL 600 mm for the milling center, this corresponds to a maximum workpiece edge length of 120 mm. This design and the resulting low moving masses enable maximum dynamics whilst maintaining high rigidity. With highly dynamic BC 5-axis kinematics, spindle speeds of up to 50,000 rpm and jerk values of up to 900 m/s³, the Micro5 XL achieves outstanding feed and machining speeds whilst maintaining maximum accuracy.
The Micro5 XL – a platform for high-productivity 5-axis simultaneous machining of complex small precision parts.
Integrated into a footprint of just 1.7 m²: the easily accessible magazine for up to 100 tools in total.
Tool changes from the turret magazine are carried out using a 4-jaw gripper – ensuring short chip-to-chip times and providing sufficient buffer capacity for rapid follow-up operations.
Precision machining of a titanium bone plate – an example of the expanded range of applications in medical technology using the Micro5 XL.
Automation as an integral part of the manufacturing concept
The Micro5 XL’s automation solutions were developed from the outset as an integral part of the overall platform. Covering an area of just 1.7 m², the Micro5 XL integrates coolant, chip and extraction management, as well as a turret magazine for up to 100 tools, directly into the machine design. When combined with one of the three tailored automation options, the result is a production solution that remains highly compact and scalable for the cost-effective machining of complex small precision parts.
The micromachine and automation system follow the same operating logic and are controlled centrally via the Micro5 XL’s HMI. Operation is consistently carried out from the front, with a direct view of the machining process. This allows several production units to be arranged side by side in an ergonomic and space-saving manner – production can be scaled according to current requirements or later as demand grows.
Variocell PICK&PLACE: automated workpiece handling
The Variocell PICK&PLACE automates the loading and unloading of raw and finished parts using a 2-axis linear handling system. The double gripper allows for a variety of gripping profiles and enables workpieces weighing up to 2.5 kg to be changed reliably within the machining area in a very short time.
A productive combination of a micro-machining centre and a Variocell PICK&PLACE system for handling workpieces weighing up to 2.5 kg.
Automated efficiency: The Micro 5 XL seamlessly switching between finished and unfinished parts in the work area.
Depending on the component height, up to 24 standard pallets measuring 400 x 300 mm can be stored – within a storage area of 3 m², which is therefore larger than the combined footprint of the machine and the automation system.
Operation is carried out via the Micro5 XL’s HMI. Jobs, automated sequences and parameters can be managed, saved and adjusted here. At the same time, a wide range of diagnostic and visualisation functions are available.
Variocell PALLET: automated pallet handling
The Variocell PALLET handles zero-point pallets and fixtures containing workpieces using a 2-axis handling system. The pallets are fed into the machining process and returned to storage once machining is complete. They are clamped using a zero-point clamping system on the C-axis. RFID-based identification ensures reliable and error-free allocation to the relevant machining processes.
»Nowadays, micro-machining requires not only precision and dynamism, but also cost-effective automation. That is why we have systematically tailored our automation solutions to the requirements of manufacturing with the Micro5 XL – from operation right through to the footprint.«
Matthias Trommer
Project Engineer Automation
The integrated storage system can accommodate up to 16 pallets with workpiece dimensions of up to approximately 120 mm. At the same time, the ergonomically designed set-up station allows for easy loading and unloading of the pallets during active machining time, in parallel with the machining process.
Variocell UNO: maximum flexibility through robotics
The third variant, Variocell UNO, adds further degrees of freedom to micro-machining. Instead of a linear handling system, a 6-axis robot is used here.
In addition to handling raw and finished parts, this allows additional process steps to be integrated directly into the production cell – such as turning, re-gripping, labelling, laser marking or minor inspection processes.
This creates a highly flexible automation platform for complex manufacturing requirements and further process integration.
For us, precision means more than just accuracy in the machining process. Particularly in sectors such as medical technology, it is also about trust, process stability and reproducible results. We developed the Micro5 XL precisely to meet these requirements.«
Marcel Rombey
Vice President Sales
Micro-machining taken to the next level in industry
By combining highly dynamic 5-axis machining, a minimal footprint and scalable automation, the CHIRON Group has consistently advanced the field of micro-machining: from high-precision individual applications to an industrially integrated production solution for small precision parts.
Highlights of the Micro5 XL
High-precision 5-axis machining
High-speed cutting
Excellent thermal stability
High static rigidity and repeatability
Up to 100 tools – for high process flexibility and reduced operator intervention
Machining cube with a maximum side length of 120 mm – for larger precision parts
Low energy consumption (average approx. 3.7 kWh) – for low running costs
Minimal footprint, including peripherals, of 1.7 m²
Micro-machining dynamically showcased
With its »Precision Beast« online campaign, the CHIRON Group has deliberately presented the Micro5 XL in a different light: in an eye-catching way and using visual imagery that goes beyond traditional machine tool marketing. The campaign slogan »Frighteningly powerful. Astonishingly versatile.« sums up the positioning and performance of the micro-machine – high dynamic performance during machining and a wide range of applications for demanding small precision parts.
The campaign also attracted attention in industrial circles. Industry platforms such as IndustryArena particularly highlighted the modern visual style and the distinctive communication approach – as an example of how technological innovation can be brought to life through communication.
