Ament Plastics Optimises Thermoset Machining with DMG Mori Turn-Mill Investment

German sub-contractor Ament Plastics GmbH, based in Wernberg-Köblitz, has been a specialist in the machining of complex components from technical plastics since its founding in 2005. With a team of 25 employees, the company primarily serves the automotive, medical, and aerospace sectors, with a focus on high-precision individual parts and small series. Notably, thermosetting plastics account for 70% of its production — materials known for their abrasive nature and machining challenges.

To streamline its processes and expand capacity, Ament Plastics invested in a DMG Mori CLX 450 TC twin-spindle turn-milling centre in 2022. This move marked a significant milestone in the company’s drive for efficiency, allowing it to complete six-sided machining in a single setup. Previously, components required multiple operations and reclamping on separate machines — a process that consumed time, tied up capacity, and risked compromising dimensional accuracy.

The CLX 450 TC, with X, Y and Z travels of 750 x 200 x 1,100mm, provides a compact yet powerful solution. It features a counter spindle and the compactMASTER turn-mill tool spindle, enabling one-hit production. A Breuning IRCO bar loader automates feeding, while a container on the outfeed side collects finished components. This setup supports unattended overnight production, significantly improving throughput and resource utilisation.

Thermosets, unlike thermoplastics, do not produce manageable chips but instead generate fine dust during cutting — creating a highly abrasive slurry. “Depending on the application, we can’t use coolant because thermosets absorb moisture,” explained founder and CEO Klaus Ament. “In such cases, we must rely on dry extraction methods.”

Materials such as epoxy glass fibre, common in thermoset laminates, are particularly aggressive and require specially hardened tools. Every plastic type demands distinct machining parameters, and Ament’s experienced engineers are critical in maintaining consistent quality.

According to Production Manager Erik Fleischmann, the investment has transformed operations: “Previously, our parts went through multiple machines with repeated setups. The CLX 450 TC eliminates that, saving time and boosting accuracy.”

The company’s space constraints also influenced the decision, with the CLX 450 TC’s compact footprint being a deciding factor. Ament’s commitment to in-process inspection further enhances quality control, with integrated measurement reducing the need for post-process inspection.

Mr Ament concluded: “In a competitive market and with the challenge of attracting skilled machinists, complete machining and process integration are critical. The CLX 450 TC has positioned us for future growth and higher efficiency.”