CNC precision machining centres, developed and build in the Kern machine tool plant in Eschenlohe, deliver optimum results in the most demanding machining
assignments — around the clock, seven days a week. The Kern Contract Manufacturing division, which is based at our Murnau plant, draws on the know-how acquired by our Mechanical Engineering team in Eschenlohe. Conversely, our many years of experience gained in manufacturing practice continually flow into the ongoing improvement and optimisation of our machines. This close interlinking of Contract Manufacturing and Machine Engineering is what makes Kern Microtechnik unique!
In many applications the focus is not on achieving a sub-2 μm precision on the workpiece, but rather on the machine’s series stability, integration capability and cost-effectiveness. The sleek Kern Micro Pro is designed to perfectly meet these requirements.
With its proprietary X-Y cross table, Kern Evo delivers maximum precision in a small installation space. The design allows maximum smoothness and excellent surface finish (Ra < 1 μm) even at high speeds and acceleration values.
Short distances between components and drives ensure minimal angle errors, while ultra-high resolution direct measuring systems guarantee maximum repeat accuracy in a working space of 300 x 300mm. Kern Evo can be optionally equipped with a 4th and 5th axis without compromising the stability and high precision of the basic machine.
With high quality components in all peripheral modules and easy automation, Kern Evo is widely used for unmanned 3-shift production in all industries that demand maximum precision on the workpiece.
Advanced technologies for maximum precision
The incorporation of sophisticated, mature technologies makes Kern Evo perfect for highly stable serial production tasks:
Driven by hydrostatic bearings and guidings, Kern Pyramid Nano is one of the most precise CNC machining centers in the world. By focusing on reliability in serial operation, this machine achieves ultra-precision manufacturing of industrial workloads.
Advanced technology for μ-accurate serial production
At the heart of the machine are the axes, which are mounted on hydrostatic bearings and therefore promise virtually wear-free precision throughout its lifetime. This means the quality and precision of all axes remain constant over extremely long time-frames. In addition, the hydrostatic system enables high acceleration with excellent vibration damping, bringing productivity and precision into perfect harmony. In combination with Kern’s proprietary temperature management system, an optimally configured machine system is guaranteed at all times.
Kern’s sophisticated, mature product technologies give Kern Pyramid Nano significant advantages in precision manufacturing:
For your machining assignment, KERN contract production offers you μ-accurate HSC (High Speed Cutting) in air conditioned rooms. With our modern machine pool, we reliably achieve highly accurate contours, sculptured surfaces and bores with form and location tolerances within ± 1 μm. This eliminates the need for precision assemblies with time-consuming adjustments.
The hydrostatic guides on the KERN Micro HD guarantee maximum precision and friction damping in absolute freedom, and truly stand out when machining hardened steel or materials hard to machine. Due to hydrostatics, we achieve an extremely high surface finish quality, significantly reducing the need for reworking (e.g. polishing).
The features of KERN contract production for HSC milling and hard milling:
Our fully air-conditioned production center contains twelve KERN ultra-high precision CNC machining centers with high speed spindles. They give us the capability to manufacture anything from prototypes to serial batches of up to 10,000 pieces. Our product range includes watch plates and movement parts, fiber optic connectors for medical endoscope heads and turbine wheels in the submillimeter range.
For serial production, we have nine automated manufacturing cells available. They offer maximum autonomy and reliable, unmanned machining around the clock (24/7) with buffer storage for hundreds of components and high repeat accuracy thanks to zero point clamping systems. Process stability is further enhanced by automatic tool exchange and correction of tool wear.
The extremely high process stability ( KERN expertise ) at KERN contract manufacturing ensures that the first part has the same quality as the ten thousandth.
The features of KERN contract production in micro-milling and micro-drilling:
EDM is a contactless machining process for workpieces with combined requirements beyond those of conventional milling, e.g. special geometries or material hardnesses. When using EDM for micro-parts and micro-structures, KERN’s contract production achieves the same precision as high conventional milling.
In order to consistently meet our high-quality standards, we produce our own electrodes and micro-electrodes for EDM on our high precision KERN CNC milling centers and test them with 3D-coordinate measuring machines.
Wire-cut EDM at KERN contract production:
CNC EDM at KERN contract production:
Latest machine technology at KERN Microtechnik
Our new Agie Charmilles Cut 3000 enables tolerances of 1.5 μm on the workpiece with a surface finish quality of up to Ra 0.05. The twin-wire system automatically changes between standard and fine wires during processing to achieve inner radii of less than 20 μm. The diameter of the wires ranges from 0.03mm to 0.3mm.
From our in-house production of high precision machine components, KERN Microtechnik has amassed enormous expertise in the manufacture of axle components, spindle beds and guide bearings for precision guidance systems.
We use surface grinding to guarantee the necessary flatness and parallelism for contact surfaces, as well as optimum surface quality. With our surface grinding machines, we achieve a flatness and parallelism of 2 microns in a 600 x 200mm area.
For maximum precision when using a combination of jig grinding and milling in a single clamping, we turn to our hydrostatic KERN Micro HD. With the 5-axis machine, we were able to reduce the processing time when grinding prismatic guides by approx. 80% compared to conventional processing using a surface grinding machine. Throughout, accuracy remained at 2 µm for parallelism and angularity.
Measuring down to the μ
Highly accurate measuring is a prerequisite for the production of micro- and high precision parts. It is therefore unsurprising that the measuring and testing equipment used at KERN contract production is correspondingly extensive and high quality. It includes more than 1,500 different measurement and testing apparatus that are regularly calibrated to the requirements of ISO 9001. Equipped with five high-end measuring machines, the KERN testing laboratory is kept at a constant temperature range of ± 0.5K.
Overview of KERN’s precision measuring systems:
Direct hard milling with Kern – your benefits
The Micro and Evo machines by Kern fulfill all of these requirements superbly. They are continually being optimized through close collaboration with internationally renowned watch- and jewelry makers. Kern Microtechnik’s patented quick-release plates vastly improve efficiency by enabling both tool changes and the processing of different articles with a variety of machining methods — even during unmanned operation over long periods.
The advantages of Kern machines for the jewelry industry: