News Archives | Staub Precision Machine, Inc.

Celebrating 50 Years of Innovation and Excellence at Staub

Staub Precision Machine Inc. — Fri, 01 Aug 2025 11:46:30 +0000

Staub Precision Machine has come a long way, from its humble beginnings in a garage off New York’s Route 75 to an industry leader working with cutting-edge CNC machining technology. This year, the company celebrates fifty years of innovation and leadership in the machining industry. Throughout the past half-century, the company has evolved considerably, though it continues to maintain a commitment to excellence that’s created enduring business partnerships and customer relationships.

The 50-Year Journey of Staub Precision Machine

In 1975, Tony Staub founded a machine shop then known as the Staub Machine Company in his garage in Hamburg, NY. Tony Staub’s entrepreneurial vision continues to inspire, while the company he founded has grown and carries on as an industry leader. In large part, Staub Precision Machine’s investments over the years have focused on new machining technology that add to the company’s capabilities. Investment in cutting-edge equipment, staff training and innovation are at the center of Staub’s success throughout this past half-century.

An Investment in Advanced Technology

Staub was adding technology and developing automated systems at a time when machine shops were only grudgingly adopting such advanced technology. This gave Staub an advantage over other shops, even enabling a nascent form of lights-out manufacturing back in the 1980s.

Integrating automated machinery and robots to conduct tasks without direct human involvement increased the amount of production the shop could do. However, automation was about more than just increasing system uptime. It pushed employees to learn and grow with the company as it stayed on top of progress within the machining industry. This constant drive to optimize operations still stands at the core of Staub Precision Machine’s development to this day.

Growing Pains: The Early Years of the Company

While Staub started with a Bridgeport mill, drill press and manual lathe in a garage, the idea was initially a simple one: bring in enough business to pay the bills. So Staub took any work that was available, though these jobs were all initially for local customers. In the early years, money from jobs largely went back into the business.

By 1980, the business outgrew the garage and the machine shop was relocated to larger premises across town on the Allendale Parkway. By the mid-1980s, however, the machine shop had become reasonably successful, allowing him to hire employees while also investing profits in new equipment and technologies. By 1995, Staub’s rapidly increasing business allowed the company to move into an even larger facility on Lake Street, formerly the site of a Super Duper grocery store.

Investment in Cutting-Edge Technology

Staub was an early adopter of 4-axis CNC milling and live tool lathes, but implementation of automation accelerated at the cusp of the 21st century. The company came to purchase its first linear pallet pool (LPP) system in 1998, followed by a second and third LPP system in 2005 and 2009 respectively. These automated pallet handling systems optimize production by enabling multiple machine tools to share use of the pool of pallets. This streamlines production by making loading and unloading of workpieces more efficient, while in turn reducing equipment downtime.

With these purchases, Staub became the biggest user of LPP technology in the region. Now seen as a pioneer throughout western New York because of Staub’s increasing use of cutting-edge technology, the company was on a roll. The LPP systems greatly improved efficiency and output, bringing in even more work. The expanding business purchased two properties about a mile away from their Lake Street machine shop in 2010 to make room for an even larger facility on Grimsby Drive, which was later renamed Staub Drive. By the end of 2011, Staub was making over 3 million parts annually.

But investing in technology doesn’t always provide a straightforward line to greater profitability. The company discovered this when they bought a million-dollar 5-axis machining center, which saw no use for a year after its purchase. That said, after a year the machine was working 95 hours per week on one job, with a second project lined up for an additional forty hours. All this was done with minimal labor costs, proof enough that the use of innovative technology still holds true over time.

Investing in Quality & Employees

In March 2015, Staub achieved ISO 9001 certification, a standard for quality management systems that’s recognized globally. With Staub’s certification, customers were now assured of the company’s commitment to consistently produce quality parts for their products. While ensuring that customers’ needs and expectations would come first, companies certified under ISO 9001 also look to continuously seek ways to improve performance and processes.

In conjunction with this quality management certification, Staub has always been dedicated to creating an expert workforce by investing in employee training programs. By increasing their skills, Staub’s workers are what help the company maintain its competitive edge. This later led to Staub obtaining their AS9100 certification in 2021, allowing them to ensure regulatory compliance in the aerospace industry. This certification, combined with improved operational efficiency, continuous improvement in their quality management systems and enhanced reputation in market, Staub has been able to grow their business and customer base within the aerospace industry.

Collaborating with & Solving Problems for Our Customers

Staub’s business model relies on customers’ success, as the company doesn’t produce or sell its own products. Rather, the parts they produce must work exactly according to their customers specifications, which is why it’s so important to build long-lasting relationships. Understanding their needs enables Staub to provide customized solutions to each customer’s unique challenges. Their customers trust them enough to give Staub a seat at their table, and it’s this collaboration between Staub and its manufacturing partners that have helped make the company a success.

For example, one of Staub’s larger customers, an aerospace company, approached Staub in the early 2000s with a project. A much larger company, they sought out Staub due to the company’s reputation for providing precision parts in quantity. Like many customers, this large company came with a problem that required a solution. As a company building systems for high level commercial and government clients, the work involved extraordinary levels of confidentiality, an uncommon requirement for most customers at the time.

Additionally, this new partnership required Staub to provide services that were on the fringe of the company’s capabilities. This included complete finishing of parts, which included deburring, helicoiling, painting and plating. Early in the relationship, this customer pressed Staub and its employees to constantly improve to meet their partner’s goals. This customer saw the potential in Staub’s operation, encouraging the company and sending personnel to provide assistance.

Today, Staub Precision Machine routinely provides thousands of these same components while turning a profit, thanks in large part to taking on this project. And those additional capabilities have become central to Staub’s offerings today. This collaboration saw Staub expand its capabilities while giving a customer exactly what they needed. In turn, the efforts our company put into this project paid off, as this same customer returned to us to help them solve another problem, meaning years or even decades worth of additional business.

When the Latest Technology Isn’t the Answer

While Staub Precision Machine touts its technological capabilities, we’ve also learned that using the latest CNC technology isn’t always the best solution. This might seem odd coming from a machine shop that takes pride in its cutting-edge CNC setup, but sometimes the most advanced technology isn’t the most cost-effective means to solve a problem. They discovered this when approached by a customer that approached them with a new opportunity that involved the drilling and countersinking of holes into customized aluminum workpieces.

With a goal of half a million parts produced annually, Staub saw that using the latest high-end CNC automation would make the project uneconomical. So, the team dealing with this problem came up with a more flexible solution, developing a customized drilling machine that ended up delivering double the necessary throughput, which in turn made the job profitable. In the end, it wasn’t technology but rather the creativity and expertise of Staub’s team that made this a successful venture.

A 50-Year Journey: Milestones of Staub Precision Machine

1975: Tony Staub founds Staub Machine Company in his garage off Route 75 with a Bridgeport mill, drill press and manual lathe.
1980: The machine shop moves from the garage to 4149 Allendale Parkway.
1980s: Over the course of this decade, the building on Allendale doubles in size.
1995: Staub moves to an even larger space at 206 Lake Street, the location of the former Super Duper grocery store.
1998: Staub’s first LPP system was also purchased in this year.
2005: Staub adds a second LPP system.
2009: Staub adds a third LPP system.
2010: Two properties on Grimsby Drive – later renamed Staub Drive – are purchased to expand Staub’s operational capacity.
2011: Staub surpasses production of over 3 million parts annually.
2013: Production more than doubles from 2011 to reach 150,000 parts per week.
2015: Staub achieves ISO 9001 certification to support its commitment to quality and consistency in production.
2018: Purchased 5-axis machining center
2019: Purchased second 5-axis machining center
2021: Integrated new automated mill-turn center
2021: Staub achieves AS9100 certification, ensuring their regulatory compliance with requirements for the aerospace industry
2022: Staub purchases land at the end of Staub Drive and announces plans to expand its Staub Drive facility.
2024: Construction of a new, 60,000-square-foot building at Staub Drive begins, consolidating some operations under one roof, with construction finishing in 2025.

Staub Precision Machine: Into the Future…

Staub Precision Machine’s success lies in the ongoing relationships and collaboration with customers that makes the company what it is. While Tony Staub passed the baton on to a new generation of engineers and operators with the private sale of the company several years ago, the deep understanding and commitment between Staub and its customer base remains strong. The future going forward is a bright one filled with continuous innovation as they continue to streamline production.

Staub will continue to promote efficiency in their operations by integrating advanced technologies that increase automation, reducing the chance of human errors. In an ever-evolving manufacturing environment, the emphasis on building enduring partnerships with their customers will continue as before. Staub Precision Machine is more than our ultramodern machinery. Staub’s ethos relies on developing relationships with people, whether it’s developing employees through ongoing training or collaborating with customers to produce exactly what they need.The vision of Staub Precision Machine in many ways remains the same as it was from the start: delivering high-quality precision parts with high-tech equipment at high volumes, while coming up with the most efficient solutions to do so. For new, old and potential customers of Staub, they stand ready to engage with customers about how we can assist with their project. To learn more about their capabilities, we invite you to contact the machining experts at Staub today.

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Scaling Up Production with Automated Solutions in Communications Manufacturing

Staub Precision Machine Inc. — Mon, 09 Jun 2025 18:53:01 +0000

Scaling Challenges for Making Communications Equipment and Solutions

Regardless of how it’s conveyed, physical mechanisms facilitate data transfers, emails, instant messages, spoken communications or other modes of transmitting information. As the complexity and capabilities of these instruments advance, older models often become obsolete. This in turn shortens their useful lifecycles, while forcing manufacturers to constantly tweak their techniques while keeping abreast of new technologies.

Modern society now relies heavily on devices that augment communications. With automated machining solutions, manufacturers can more rapidly and reliably manufacture physical components for devices used in communications. Automated solutions offer manufacturers the ability to truncate turnaround times, enabling them to bring items to market more quickly.

Precision machining is needed to produce many of the constituent parts that make up communications equipment. Automated machining solutions help operators meet exacting standards necessary to ensure end product quality, as any lapse can reduce consumers’ trust and, as a result, affect profits. Automation also largely removes the risk of human error while helping streamline production processes.

How Automation Tackles Manufacturing Challenges

What has often been referred to as the Fourth Industrial Revolution relies on the seamless integration of robots and smart devices into production systems, all controlled via software. These technologies work together to automate the manufacture of machined parts. Solutions involving automation reduce bottlenecks and other inefficiencies while also creating largely error-free processes.

Programmable CNC machinery gives parts manufacturers greater flexibility when designing and fabricating precision parts made for communications. Automated solutions utilizing CNC technology aid operators in programming pathways to provide consistency in workpieces. Additionally, with the help of CAD and CAM software, adapting designs becomes far easier. This allows companies to quickly change designs according to customer needs.

How Automated Solutions Benefit Communications Manufacturing

When constructing precision parts or products used for communications, automated solutions augment efficiency, deliver consistent quality, ensure better performance, offer greater flexibility, and provide cost savings over time. Automated solutions shorten delivery times while allowing manufacturers to meet ever-increasing demand. Automating quality control systems allows manufacturers to detect defects in real time and optimize other processes by integrating IoT devices into the production system.

Automated solutions can provide the following benefits:

Higher quality parts with more consistency
Better resource allocation
Decreased labor costs
Faster production
Greater uniformity of components
Guaranteed performance
Increased productivity
Less reworking of workpieces
Lower operating expenses
Reduced lead times

These advantages allow manufacturers greater flexibility when fabricating components for next-generation communications.

Implementing Automated Solutions

It’s important to identify the best technology for the job, which involves careful assessment of production bottlenecks to determine which types of automation to use. For example, advanced software streamlines workflows through precise programming of toolpaths, while it also helps with prototyping, real-time monitoring, and scalability. Meanwhile, AI-driven manufacturing systems enable process optimization, predictive maintenance, and data-driven analytical insights while reducing downtime and improving quality control.

Unlike industrial robots, automated cobots (collaborative robots) work safely and efficiently alongside humans, giving automated facilities greater flexibility while also lowering labor costs and enhancing productivity. Additionally, custom tooling for CNC machines can improve processes, so this should also be considered. However, there’s still a role for skilled workers in automated facilities.

Creating a hybrid environment where humans oversee operations is often the optimal strategy. Phasing automation into precision machining and manufacturing systems should always be strategic, with long-term return on investment a primary goal. In this way, communications equipment manufacturers and other industrial customers can better scale their operations and gain competitive advantages over the competition.

Real-World Automated Solutions for Communications Manufacturing

Staub Precision Machine has ample experience collaborating with manufacturers involved in making products and parts used in communications. Automated solutions for their partners include helping a customer in the medical industry that was unexpectedly inundated with orders. Their previous suppliers were unable to keep up with demand. Originally a forged component, Staub recommended utilizing our DMU-60 5-axis mill paired with a robotic loading cell to meet their needs. This resulted in better precision, while also meeting the customer’s demand.

In another cooperative effort, an aerospace company needed tolerances for micro-components of communications devices that were between +0.001/-0.000 inches (+25.4/0.000 microns) with 100 percent inspection, while dimensions tighter than +/-0.001 inches (+/-25.4 microns) needed to be reported. At the time, Staub’s quality control system couldn’t keep up with inspections during working hours, so they implemented an automated inspection system with a customized computer-aided robotic loading system, or CARL for short. This resulted in fewer defects and higher customer satisfaction.

When it comes to communications, automated solutions from Staub can help you scale production. Automation brings better consistency, higher efficiency, and improved quality. To learn more about our capabilities, contact Staub’s precision machining experts.

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The Future of Automated Manufacturing in Aerospace

Staub Precision Machine Inc. — Wed, 07 May 2025 13:51:00 +0000

Aerospace manufacturing demands precision, efficiency, and repeatability. As the industry pushes for lighter materials, tighter tolerances, and faster production cycles, automation continues to reshape how components are made. At Staub Precision Machine, we have invested heavily in automation to improve consistency and scale production for aerospace applications.

How Automation Advances Aerospace Manufacturing

Aerospace automated manufacturing has evolved to include robotic machining, automated inspection, and unmanned production cells. These technologies help reduce variability, lower costs, and increase throughput. We integrate robotics with CNC machines to streamline operations, allowing us to run high-precision jobs with limited manual intervention.

Automation improves part quality by reducing human error. Our CNC equipment, paired with robotic loading systems, maintains tight tolerances without interruptions. With multi-axis machining centers operating alongside automated guided vehicles (AGVs), we can move raw materials and finished parts efficiently across the shop floor.

Meeting Aerospace’s High Standards with Automation

Automated processes help us comply with aerospace industry standards, including AS9100 certification. This certification demands strict quality control measures and traceability throughout production. With automation in place, we can document every step of the manufacturing process while maintaining a consistent output.

High-precision machining is essential for aerospace components that must perform under extreme conditions. Our robotics minimizes material waste by optimizing each cut, ensuring that forged titanium or aluminum billets are used efficiently. The result is high-quality parts produced in less time and with fewer defects.

Precision Through Robotics and Smart Technology

Traditional machining requires constant supervision, but automation allows us to run lights-out production. Our automated manufacturing systems handle loading, unloading, washing, and inspection without operator input. This approach not only reduces labor costs but also improves repeatability in every batch.

We use vision-guided robotics for real-time quality control. High-speed measurement systems check dimensions as parts come off the machine, eliminating potential errors before they reach final assembly. Automated inspection ensures that aerospace components meet exact specifications before they move to the next stage of production.

The Role of Flexible Manufacturing Systems

Flexibility is essential in aerospace production since parts come in various sizes and complexities. Our flexible manufacturing systems (FMS) allow us to switch between jobs without lengthy setup changes. By using palletized automation with 5-axis machining, we complete multiple operations in a single setup, reducing downtime between runs.

With robotic workpiece handling and intelligent scheduling software, we optimize production across multiple machines simultaneously. This approach helps us meet the growing demand for aerospace components while maintaining short lead times.

What’s Next for Aerospace Automation?

The future of aerospace automation will focus on even smarter robotics and AI-driven decision-making in manufacturing processes. Cobots—collaborative robots—will likely play a larger role in handling complex assemblies where full automation isn’t yet possible. Advancements in additive manufacturing may also integrate with automated machining for hybrid production methods.

At Staub Precision Machine, we continue to invest in new technologies that shape the future of aerospace machining. Our goal is to push efficiency further while maintaining the precision required for mission-critical applications. As aerospace demands evolve, automation will become even more indispensable in meeting the industry’s exacting standards.

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Precision Medical Device Production with Advanced Equipment

Staub Precision Machine Inc. — Tue, 22 Apr 2025 13:41:00 +0000

Medical device production requires strict attention to precision, consistency, and quality. At Staub Precision Machine, we combine advanced machining technologies with automated manufacturing to create reliable components for the medical industry. Our experience in high-precision manufacturing ensures that every part meets demanding specifications while maintaining efficiency and repeatability.

Precision Machining for Medical Devices

Medical components often require tight tolerances and complex geometries. Our precision machining capabilities include CNC turning, CNC milling, 5-axis machining, and EDM machining. These processes allow us to create intricate features while maintaining accuracy across high production volumes.

To meet the medical industry’s rigorous standards, we use cutting-edge equipment designed for consistency and reliability. Our rotary transfer machining and automated milling systems help reduce variability, ensuring each component meets exact specifications. Whether producing surgical instruments, prosthetic parts, or diagnostic equipment components, we maintain strict dimensional accuracy throughout production.

Our experience with various medical-grade materials, such as stainless steel and titanium, ensures that each part meets the required performance and durability standards. From complex implantable components to disposable medical device parts, we apply precision machining techniques to achieve the right balance of strength and accuracy.

Automation in Medical Component Manufacturing

Automated systems increase efficiency and reduce human error in medical device manufacturing. Our automated manufacturing solutions include robotic loading, automated inspection, and precision cleaning processes. These systems enhance consistency while accelerating production timelines.

By integrating robotics with CNC machining centers, we streamline repetitive tasks such as material handling and quality checks. Automated guided vehicles transport parts between workstations, while robotic arms handle loading and unloading operations. This allows us to maintain a seamless workflow that minimizes downtime and maximizes efficiency.

Automated wash systems remove contaminants from components before final processing to meet medical cleanliness standards. Coolant management systems further improve machining precision by creating stable operating conditions that reduce material inconsistencies. These automated controls work together to uphold strict industry requirements for cleanliness and part integrity.

Strict Quality & Inspection Standards

Every medical component must adhere to rigorous regulatory requirements. Our quality & inspection processes incorporate CMM machines, laser micrometers, and vision measurement systems to verify part accuracy down to a micron level.

We maintain ISO 9001 certification, emphasizing strict process controls and material traceability from raw materials to finished products. Every part undergoes multiple quality checks using advanced inspection techniques to ensure it meets exacting tolerances and specifications before shipment. By implementing automated inspection technology, we minimize variability and detect any defects before parts leave our facility. This commitment to quality helps medical manufacturers maintain compliance with industry regulations while delivering dependable products.

Supporting the Medical & Healthcare Industry

We specialize in high-precision manufacturing for medical & healthcare applications, including prosthetics, surgical tools, diagnostic equipment, and other critical components. Working closely with customers during the design phase, we help optimize manufacturability while improving cost efficiency and lead times.

Whether you need complex custom parts for implants or high-volume production runs for disposable medical devices, we have the technology and expertise to deliver accurate results on time. Our ability to automate production processes further minimizes costs while maintaining the highest levels of precision these applications demand.

Work With a Trusted Manufacturing Partner

Precision in medical device production is essential for performance and regulatory compliance. At Staub Precision Machine, we combine expertise, automation, and rigorous quality control to meet the demands of the healthcare industry. Contact us today to discuss your project requirements or request a quote to learn how our capabilities can support your manufacturing needs.

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Importance of the CNC Machining Industry to the Entertainment Sector

Staub Precision Machine Inc. — Mon, 07 Apr 2025 13:17:00 +0000

The US entertainment industry is worth nearly $650 billion annually, covering concerts, conferences, film, television, digital streaming, live stage performances, speaking events, theme parks, and other events. The CNC machining industry has quietly become an increasingly important player within this vast sector. Performances of all types require equipment and rigging that depends on the accuracy provided by CNC machining. Industry insiders in the entertainment sector understand how CNC technology has become a vital yet largely unnoticed part of many performances and events.

Where the CNC Machining Industry & Entertainment Meet

CNC machines can form items from many different materials with incredible detail and precision, making them vital elements for stage and other entertainment events. For an array of parts used in various equipment and systems, the CNC machining industry has become integral for making components for the entertainment industry. Programmable CNC machines can readily reproduce items for events management as well as film and television productions. Additionally, CNC machines can work with alloys and metals, composites, plastics, or other materials to suit any production need.

Some of these entertainment industry applications include:

Camera tripods
Communications equipment
Crowd control barricades
Lighting, projection, sound, and video systems
Modular stage risers
Parts for fog, pyrotechnic, rain, smoke, snow, wind, and other special effects machinery
Permanent stage platforms
Rigging apparatus
Slip hinges and other hardware used for stage scenery
Stands for microphones

While digitized or 3D-printed props have their place in the entertainment sector, the CNC machining industry’s capabilities can streamline prop production. Its versatility makes it a go-to technology for all types of entertainment events and productions. CNC equipment like EDM(electrical discharge machining) and 5-axis milling machines provides an efficient means to fabricate molds for mass-producing injection-molded prop items, offering greater accuracy than those made with 3D printing.

CNC Machining Industry in Film Production & Management Events

Various movie productions have additionally relied on CNC machining over the past few decades. In 2014, for example, CNC machines were used to fabricate sets and props for Interstellar. The CNC machining industry is involved in more technical aspects of filmmaking as well, helping to bring a character’s action to life. The SnorriCam rig that attaches to an actor requires complex components with tight tolerances made by the CNC machining industry to create unique and dynamic visual effects.

CNC technology often hides in plain sight in events and productions. Precision machining of brackets, housings, mounts, and other complex components used in lighting systems ensures stage events go off without a hitch. Audio/visual equipment parts, like projecting devices or speaker casings, often require tight tolerances that other types of production, like 3D printing or injection molding, just can’t achieve.

Many of the components for the entertainment industry are made from less expensive metals like aluminum or its alloys. Aluminum is used not just due to economics but because it’s lightweight yet strong and is also suitable for CNC machining. In the entertainment industry, this work is often done with 5-axis CNC machines, which can produce large volumes of complex components quickly. These high-tech CNC machines need fewer setups, with their operation supporting longer tool life, closer tolerances, and better surface finishes.

The Staub Difference in CNC Machining for the Entertainment Industry

Staub Precision Machine Inc. provides a wide range of services. This includes CNC machining for the entertainment industry. Staub’s automated setup makes us especially adept at large-scale production, for which we can assist in the design phase through production, including finishing work. Staub can make a wide array of components for the equipment used for stage performances, political events, major concerts, and other large live events. To learn more about our capabilities, contact the machining experts at Staub today.

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5 Reasons to Choose Automated CNC Machining for High-Volume Production

Staub Precision Machine Inc. — Thu, 06 Feb 2025 12:34:10 +0000

Automated CNC machining has helped make fabrication methods like just-in-time manufacturing and lights-out production feasible in high-volume production. When fully automated, CNC machines can achieve far greater efficiency and productivity than processes in which human workers are needed. Automated CNC machines have become standard in many machine shops, enabling them to replace personnel in activities that are especially hazardous and repetitive while increasing quality and precise tolerance.

Implementing automated CNC machines in production guides assembly, inspection, loading, unloading, and other operations using software rather than human management. This, in turn, allows a single employee to supervise several machines simultaneously. For some machine shops, this can even be done remotely. Automation also reduces costs, heightens safety, and reduces lead times, allowing manufacturers to boost production and become more competitive. The increased automation and repetition allow for high levels of consistent quality.

How Do Automated CNC Machines Aid Mass Production?

CNC technology allows machine shops to make precision parts far more quickly and in greater volume, while also improving quality and consistency in the items produced. Manufacturers can more easily scale their production by producing components at higher volumes. Decreasing fabrication times also allows manufacturers to produce more items in less time than conventional methods.

This is a crucial goal of mass production, which has brought the modern world a remarkably high standard of living. High-volume manufacturing lowers manufacturing costs by making manufacturing faster and more efficient and reduces the price per unit. When automated, CNC machines perform operations once done manually better and with minimal supervision than those once done by humans.

5 Ways in Which CNC Machining Augments High-Volume Production

The high degree of accuracy required for precision parts has made automated CNC machines a preferred fabrication method. CNC technology can be found in modern mills, lathes, turning centers, mill-turn centers, electric discharge machines (EDMs), laser cutters, waterjet cutters, and other equipment preprogrammed to produce various components. Using highly automated systems, CNC machines convert the language used to create computer-aided design (CAD) models into instructions for the tooling.

Using preprogrammed paths for cutting components, automated CNC machines incrementally remove bits from a piece of solid material until it reaches its final form. Though standard tolerances of +/- .005 inch (0.127 mm) are commonly applied, CNC machining can achieve even greater accuracy. Tolerances down to the micron range – less than one ten-thousandth of an inch – have become possible with specific, more sophisticated CNC machines.

To achieve this, machine shops must use the highest quality tooling to achieve the precision necessary. The greater the accuracy required for a part, the more complex the tooling and programming needed. Automated CNC machines are also often used to finish off components made via additive manufacturing, as 3D printing tends to produce less smooth finishes. Additionally, CNC machining is used to create molds for injection and other types of industrial molding when mass-producing precision parts.

Optimizes Efficiency

Optimization of fabrication processes to make them more efficient often involves automated equipment. CNC machines that utilize automation tend to use much less energy and reduce the amount of scrap produced. Through this greater efficiency and decreased waste, machine shops can reduce their impact on the environment, while also reducing their operational expenses.

Automated CNC machines provide the means for:

Greater amounts of uptime
Just-in-time manufacturing
Lights-out production methods
Performing secondary operations like deburring, gauging, and washing
Quick and easy changeovers of tooling and other components
Real-time communications with other equipment

Advanced CNC machines are made to fit into places where space is limited. Essentially robots, these automated CNC machines also offer an efficient means to utilize workspace.

Consistent Results

Closely connected to efficiency is the consistency of what automated CNC machines produce. Parts manufacturers must ensure that the components they manufacture don’t vary much, which is easier with an automated production system. CNC machines support consistency in fabrication far better than human machinists working on manual machines. The software integrated into a computerized CNC machine allows for reliable prediction of every tool’s movement, ensuring the exact toolpaths are followed. Automation results in a more consistent product, and once a toolpath is programmed, it allows higher volumes of components to be made consistently and in less time.

More Cost-Effective

The speed and precision of automated CNC machines are the underlying factors affecting the quality and expense of machined parts. This is especially true for more complex components. The production speed allows more parts to be made in a shorter time frame, while accurately applied tooling reduces waste. When combined, these make the use of CNC technology particularly cost-effective.

Most automated CNC machines can perform the work of between three and five people performing conventional machining tasks. When fully automated, CNC machine centers working on multiple axes and with advanced monitoring capabilities can replace up to ten machinists, especially when robotic systems for loading and unloading are included. This saves not just on labor costs but also lowers energy use per unit produced.

Fully automated CNC machines can work continuously and unintended around the clock. When able to operate constantly, machine shops can produce more components that are more cost-effective. With automated processes supported by manufacturing software, tooling changeovers can be performed seamlessly to diminish cycle times and produce parts at a lower cost per unit. This, in turn, allows machine shops to have shorter lead times, making manufacturers more competitive.

Lower Labor Requirements

With automated CNC machines, manufacturing processes require fewer workers. Even with a small labor force, it’s still possible to simultaneously have numerous projects on the go, as accuracy and speed increase when production is automated. CNC machines also require much less attention so employees can focus on other tasks for which humans are better equipped, like designing components for new customers. Automation doesn’t just mean saving on labor, however. It also allows a shop to increase output, boosting profitability.

Better Quality Control

Regardless of the type of manufacturing, quality control is far easier when automated. CNC machines enhance quality by removing almost every means of human error from the process. They allow machine shops to make components with extraordinarily tight tolerances to meet industry or regulatory standards. Advanced quality control methods are sometimes even integrated into automated CNC machine systems to give manufacturers greater confidence that the machined goods they produce are of the highest quality.

Automated CNC machines can support quality control by performing:

Data analytics: Automated CNC machines with integrated analytics software can gather vast amounts of production data that help manufacturers make informed decisions on improving the components in their products.
Monitoring tool condition: Using devices that measure wear and combined with monitoring systems that are automated, CNC machines can constantly scrutinize the condition of tooling and predict when it requires replacement.
On-machine inspection: Probing systems for machine tools integrated into automated CNC machines allow inspections during production, enabling real-time corrections.
Real-time monitoring: Collection of data regarding amount of cutting force applied, spindle speed, and wear of tooling allows operators to more quickly identify issues and make real-time adjustments to a machine’s configurations.

Automation can even prioritize production to enable quicker turnarounds and to better fulfill orders.

The Staub Difference in Automated CNC Machining

At Staub Precision Machine, we understand that the future is automated. The CNC machines used by our machine shop are highly automated, and Staub continues to automate our systems to reduce human intervention. Staub’s advanced systems provide our customers with efficient, consistent, cost-effective, and labor-saving means to improve the quality of our parts and products. To learn more about our precision machining capabilities and how we can help scale up your production, contact the machining experts at Staub today.

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Custom Machining Services: Understanding the Equipment

Staub Precision Machine Inc. — Thu, 12 Dec 2024 13:16:00 +0000

Custom machining services involve methods such as CNC milling, CNC turning, or electric discharge machining (EDM), and in many ways, it’s like customizing anything. As a tailor might take in here and let out a bit there to make a suit fit a specific person, an engineer making a custom part will produce one that fits a customer’s needs exactly as it should. Custom machining services can make parts with finer tolerances and are often the best choice for fabricating components with specific requirements; universal or standardized parts aren’t often needed for these types of customized projects, as the end product has a very specific purpose.

Custom machining services are often used when:

A high-quality component needs to be delivered quickly.
Features from different components can be combined into one component.
Nonstandard components are needed but not readily available.
Only smaller quantities are needed.
The part requires specific characteristics not found in standard parts.

Types of Equipment Used for Custom Machining Services

Used as a means to meet high-tolerance specifications when fabricating components, custom machining operations are performed by various kinds of CNC equipment. Deciding on the best machinery for a specific workpiece depends on the exact application and its requirements.

CNC Milling

This involves a rotating device that physically cuts away material on a workpiece and may be usedto chamfer, slot, or thread a component to create particularly complex and intricate designs. Custom CNC milling can reach tolerances within 0.01 mm (less than 2500th of an inch). Such custom machining services can be used for milling forms, gears, and the surfaces of parts made from various metals and alloys, as well as from plastics, to name a few.

CNC Turning

This method is often used to make cylindric components like bushings or shafts. In this process, the CNC machine controls the cutting tool while the workpiece spins axially. Custom CNC turning involves removing material until the part has the proper diameter and other geometrical features. This type of custom machining uses either a fixed or sliding head, with the latter type used to decrease price and production time.

CNC Laser Cutting

This custom machining technique uses laser beams to vaporize, melt, or remove material, often employing a guidance system and optics in conjunction with the laser. It involves reflecting and amplifying the laser beam with a mirror to focus energy onto the workpiece and cut away at it. CNC laser cutting reduces waste and is often used with a wide array of materials.

CNC Drilling

This CNC technique is used to produce cylinder-shaped holes in a workpiece. By utilizing drill bits with multiple points, workpieces can have holes drilled at an angle or perpendicularly. Angular drilling requires clamping devices and configurations specially programmed into the machine for performing operations like countersinking, reaming, and tapping. Perpendicular drilling simply involves an insertion into the workpiece by a rotary drill aided by a CNC machine.

Electric Discharge Machining (EDM)

This method is sometimes used for conductive workpieces because of their non-contact machining, precision, ability to machine hard materials, wire-cut capability for complex shapes, heat-affected zone control, and the production of burr-free surfaces. EDM involves transmitting sparks through a dielectric fluid that transfers electric energy from an electrode to the part’s surface. Precision EDM techniques are used for machining fine features like diameter holes and di cavities. Custom machining services that utilize EDM technology determine the discharge rate and thermal energy needed by looking at a metal’s conductivity. Additionally, EDM processes don’t require any mechanical force.

Choosing Staub for Custom Machining Services

Staub Precision Machine offers custom machining services utilizing various CNC technologies and equipment. One of the primary advantages of working with Staub is that our precision machining of custom components stems from automated production processes, leaving you with fully finished components ready for immediate use. To learn more about our capabilities, contact the expert team at Staub Precision Machine today.

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Advanced Precision Machining Techniques for High-Volume Parts Part 2

Staub Precision Machine Inc. — Tue, 01 Oct 2024 11:42:28 +0000

Welcome to the second part of our series on advanced machining techniques for high-volume production. In this installment, we’ll expand on our previous discussion about precision grinding and 5-axis CNC machining to explore new methods transforming industries like automotive, aerospace, and medical manufacturing. These techniques enhance speed, accuracy, and efficiency while ensuring the strict tolerances needed for quality and innovation in large-scale production. Join us as we continue to examine the importance of precision and the technological advancements driving industry progress.

In the ever-changing world of manufacturing, advanced machining techniques are essential for increasing precision and efficiency. From laser cutting to rotary transfer machinery, these methods are revolutionizing the production of complex components in fashion, electronics, automotive, and aerospace industries. This blog post explores these cutting-edge techniques, showing how they improve accuracy, reduce waste, and streamline production.

Mastering Precision: A Look into Advanced Machining Techniques for Complex Creations

Electrical Discharge Machining (EDM)

Electrical discharge machining (EDM) shapes workpieces through controlled electrical sparking. This advanced machining technique is also known as die sinking, spark eroding, spark machining, or wire burning. The process involves placing a workpiece beneath an electrode wire on an EDM machine, where electrical discharges from the wire concentrate heat. This heat produces the desired shape or feature by melting small portions of the material, which electrolytic fluid then flushes away. EDM is ideal for use with harder materials that are difficult to machine, enabling the creation of angled or tapered structures, minute holes, precision slots, and other complex features.

Waterjet Cutting

Instead of plasma, waterjet cutting slices through materials with a pressurized jet of water, often mixed with ceramics, glass, metal, stone, or other abrasive material. Advanced machining techniques like waterjet cutting are known as cold processes, as they’re ideal for temperature-sensitive materials, preventing hardening of the material and thermal distortion. Able to produce intricate shapes like bevels, corners, and pierced holes, waterjets also create clean edges, form complex geometries, and result in minimal waste without compromising structural integrity. Waterjet cutting works well for robust or more delicate workpieces, making it useful for the automotive, architecture, and aerospace industries.

Laser Cutting

This thermal process uses a laser beam rather than a physical one to perform advanced machining. Techniques that implement lasers allow machinists to create parts with complex geometries that other methods cannot produce. This process also enables trimming a workpiece until the edges are smooth and clean, focusing the laser to burn, melt, or vaporize the material. Laser cutting can accurately engrave or cut materials like fabrics, metals, alloys, plastic, and wood. Highly efficient, laser cutting helps create finer details on workpieces, which makes it particularly useful for the fashion, electronics, automotive, and aerospace sectors. Since it’s a process that doesn’t require direct physical contact, it reduces material distortion, making this method perfect for prototyping and mass production with various materials.

Rotary Transfer Machining

For the mass production of precision parts, rotary transfer machining entails mounting a workpiece on a rotating table, which then moves around to various stations. Each machining station performs a specific task, such as tapping, milling, or drilling. Workpieces can even be machined simultaneously to decrease production time, with the machine performing processes on different workpiece areas simultaneously. Though setup can be pretty complicated, once the rotary transfer machine is programmed, it’s among the advanced machining techniques most well-suited for mass production. Made to reduce handling and minimize downtime caused by setups, these machines allow multiple actions during each cycle. The high accuracy and repeatability of the process make it ideal for producing components with tight tolerances for the plumbing, automotive, and aerospace industries.

How Advanced Machining Techniques Drive Precision and Innovation

As we wrap up our look at advanced machining techniques, it’s evident that these innovations are transforming industries by boosting precision, efficiency, and creativity. Technologies like EDM, 5-axis CNC machining, and waterjet and laser cutting make manufacturing processes more complex and refined. By adopting these advancements, manufacturers can meet modern production demands and expand what’s possible in fields like automotive and aerospace. The future of machining is promising, and the journey toward better precision and innovation continues.

Staub Precision Machine Inc. has been at the forefront of using advanced machining techniques to produce precision parts with complex geometries. To learn more about our capabilities, contact our skilled technical personnel today.

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Advanced Precision Machining Techniques for High-Volume Parts Part 1

Staub Precision Machine Inc. — Thu, 26 Sep 2024 11:43:54 +0000

Welcome to the first part of a two-part series on advanced machining techniques. In this installment, we explore precision grinding and 5-axis CNC machining. These essential methods transform automotive, aerospace, and tool manufacturing industries by boosting speed, accuracy, and efficiency. As leaders in this field, we dive into the details, showing how these processes enhance quality and drive industry progress.

The Importance of Tolerances in Advanced Precision Machining

Precision parts need high accuracy, no matter the industry. Even with advanced machining techniques, mass-producing components identically is challenging. In parts manufacturing, tolerances are the acceptable deviations from design parameters that still allow components to function properly in the final product. However, most CNC machining tolerances are extraordinarily tight, diverging very little from one part to another.

To achieve these tight tolerances, an array of advanced machining techniques can ensure measurements fall within an acceptable range. CNC technology is key to fabricating many precision parts, with these advanced machining techniques achieving standard tolerances of at least ±0.005 inch (127 microns). Certain machines can attain an accuracy of ±0.0000984 inch (2.49936 microns) or even less. Reaching such close tolerances can require extensive processes that take significant time; these highly accurate tolerances are generally reserved only for critical components.

Manufacturers aim to produce parts with exceptional surface finishes and tight tolerances using cutting-edge precision machining methods. These techniques leverage CNC technology, computer-aided design, and automation, reducing waste, enhancing efficiency, and improving product quality. Particularly crucial in aerospace, automotive, defense, and medical sectors, these techniques shine when mass production is essential.

CNC Milling

This method shapes stationary workpieces with a cutting tool attached to a CNC milling machine. These rotating tools perform advanced machining techniques that primarily shape peripheral and face-milled features. Peripheral milling involves slots, threads, and other deeper, hollowed-out features, while face-milled features are generally shallower and carved into flat surfaces. CNC milling can include boring, contouring, drilling, engraving, facing, milling and tapping, and machining methods, primarily fabricating components generally shaped like rectangles or squares.

CNC Turning

In contrast to CNC milling, CNC turning rotates the workpiece as stationary cutting tools shape it, using turning centers, sometimes referred to as CNC lathes. The cutting tools move linearly on the turning center to remove material around the workpiece’s perimeter to achieve the desired diameter and other features. CNC Swiss lathes provide better support for tighter tolerances while shaping the workpiece, which is held by guide bushings as the machining tool shapes it. Advanced machining techniques by turning centers can create external and internal features, including boring, broaching, drilling and reaming holes, slotting, tapering, tapping, and threading.

CNC Mill Turn Machining

In addition to machinery that mills or turns workpieces, certain CNC machines have hybrid capabilities that make them the ultimate in CNC machining multi-taskers, allowing them to perform particularly advanced machining techniques. With mill/turn machining, complex components can be shaped in a single setup without changing machines. Mill/turn machines can turn parts while rotating tools are applied to mill and cross-drill a workpiece. Using sub-spindles, they can machine two components simultaneously, passing parts from one stage to another. This machining technique enables accuracy without compromising production efficiency by reducing the number of steps and setup times.

CNC Drilling

CNC drilling involves producing cylindrical holes within a workpiece like its manual equivalent, though the automated method is considerably more advanced. Machining techniques for CNC drilling processes can be performed on various CNC machines, including drill presses, milling machines, and turning centers. Machining of holes also often involves equipment with multiple points for drill bits, a design that keeps chips from damaging workpieces during production.

Drill bits often used for CNC machining operations include:

Chucking reamers
Drill presses
Peck drills
Screw machine drills
Spotting drills

Existing holes are made larger with checking reamers, while drill presses perform custom drilling. Using peck drills decreases the amount of chips and other waste generated when fabricating a workpiece. Screw machine drills can produce holes without the need to create a preliminary starter hole. Spotting drills are often used to make shallow or starter holes.

CNC Plasma Cutting

CNC plasma cutting requires that the material used be conductive, which includes metals and alloys like aluminum, brass, copper, and various types of steel, including stainless steel. Plasma cutting cuts through these materials with an ionized gas jet moving at high velocity. Essentially a plasma torch, plasma cutting machines operate at temperatures of more than 50,000°F (27,760°C), easily cutting through and melting workpieces. It produces precise and clean cuts quickly, making it practical for both thick and thin materials while producing minimal distortion in the workpiece. It’s an ideal machining technique used in aerospace, automotive, construction, metal fabrication, shipbuilding, signage, and other sectors.

CNC Precision Grinding

Though advanced machining techniques for complex components that use CNC turning centers or mills can achieve extraordinarily tight tolerances, their surfaces are often slightly irregular. Using an automated abrasive wheel, precision grinding removes excess material to provide a workpiece with a fine surface finish and a highly accurate one. This finishing method is fundamental to forming precision parts like bearings, molds, and shafts so they have smooth surfaces and are geometrically exact. For this reason, precision grinding is often used in tool manufacturing, automotive, and aerospace sectors.

5-Axis CNC Machining

Able to move simultaneously along five different axes, 5-axis CNC machining allows greater accuracy than conventional 3-axis machining, which functions only along the X, Y, and Z axes. With two additional axes – generally referred to as A and B – methods for 5-axis machining allow greater flexibility. This machining method can often make complex components without repositioning the workpiece, often enabling work to be done in a single setup.

As one of the more advanced machining techniques available, 5-axis CNC machining can:

Decrease the time it takes to machine a workpiece while minimizing waste, setups, and manual intervention.
Improve precision to cut through material more intricately, producing more accurate angles.
Shape complex and curved geometries for various industries.

Used in sectors such as the medical, automotive, and aerospace industries, 5-axis CNC machining requires less supervision than conventional methods while augmenting quality and reducing the time required to produce complex components.

Contact us today for precision machining solutions tailored to your industry needs to learn how our advanced techniques can enhance your production process. Let us help you achieve greater efficiency and accuracy in your projects, and stay tuned for the next part in Advanced Precision Machining Techniques for High Volume Production.

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Why OEMs Choose Onshoring in Today’s Global Climate

Staub Precision Machine Inc. — Fri, 06 Sep 2024 12:59:07 +0000

Many US-based corporations that previously outsourced their production to places overseas are now looking towards sourcing production back to the United States, a process often referred to as reshoring or onshoring. Over the past few decades, manufacturing has moved from more developed economies like the United States to developing countries like China. However, ample calls for “Made in the USA” products have been louder over the past few years. The pandemic reaffirmed the need to source domestically, as offshored components became increasingly scarce as pandemic-related lockdowns negatively affected supply chains.

While the US machining industry had already seen some original equipment manufacturers (OEMs) talking about onshoring manufacturing in the late 2010s, the supply chain debacles of 2020 greatly encouraged this. OEMs will unlikely move all their machining business back to domestic machining companies, as globalization has created an interconnected web of manufacturers and distributors. Yet supply chains remain unstable with current sanctions, trade wars, and major military conflicts, so onshoring manufacturing is becoming increasingly attractive to many US-based OEMs.

Why Onshoring Manufacturing Makes Sense

Once seen as a panacea to lower labor and other production costs, US manufacturers offshored much of their production from the 1980s onwards. However, as costs rise in other industrialized countries, the economics have shifted, making it less cost-effective to offshore production. Perhaps more importantly, the changing political climate and high tariffs for Chinese components have made offshoring to China less tenable. Manufacturing by OEMs has been moving back, especially for high-precision machining of components, as accuracy, labor, shipping, and quality have made the cost of doing business within the United States much more competitive.

Onshoring manufacturing doesn’t just mean bringing production back to domestic suppliers. It also means homegrown US companies that didn’t move production overseas are expanding their operations locally, either by nearshoring – moving production to neighboring countries – or onshoring. Manufacturing giant China seems to be losing some of its dominance as a destination for OEM manufacturing as US parts producers automate their operations, and problems inherent in outsourcing to overseas manufacturers have become increasingly apparent.

Resolving Supply Chain Issues by Onshoring Manufacturing

The world saw logistics and production issues contribute to broken supply chains in 2020, as factories throughout China were often locked down for weeks. Since so much global production had moved to China, this led to global shortages of various machined and other components. Added to this were higher costs for shipping, which inflated prices not only for parts but also for finished products. Onshoring manufacturing closer to end markets reduces this risk while saving time and transport costs. When an OEM’s components are produced closer to where they’re needed, it becomes more cost-effective for onshore manufacturing.

Though the 2020 pandemic lockdowns disrupted global supply chains considerably, conflict in Ukraine has also caused considerable disruption to supply chains, along with the imposition of trade restrictions with certain overseas producers. While OEMs will still need to deal with events affecting supply chains domestically, like chronic labor shortages and natural disasters, some have decided that the problems inherent in overseas production now outweigh any risks associated with onshoring manufacturing. Yet, there will always be a need to offshoot components like computer chips, LEDs, and other electronics, which are almost exclusively made outside the United States.

Trade Restrictions

Another factor played out over the past few years is the trade restrictions that have strained the relationship between the United States and countries with whom they trade, including the European Union and other Asian countries. Though the current US administration has pulled back from vocal support for trade wars, there continue to be considerable restrictions in trade concerning precision machined parts and machinery. Though China is not a source for most precision components, the current US administration has placed even more restrictions regarding technology transfers, making Chinese companies less useful as partners for OEMs that require precision machining.

Technology & Location

The key to onshoring manufacturing for OEMs, especially when machining precision components, involves cutting-edge technology. New technologies like artificial intelligence (AI), machine learning, and the Internet of Things (IoT) drive innovation, giving US machining companies an edge over those in many developing countries. For this reason, many companies seek companies positioned in or near high-tech corridors throughout the country when looking into onshoring. According to The Boyd Company – a location consulting firm that works with aerospace manufacturers – many OEMs look first at areas along important interstate highways or near transit hubs when selecting sites for onshoring. Manufacturing companies need to be near areas with considerable infrastructure and close to labor markets that can provide a reliable pool of highly skilled workers.

Why ESG is Important

Another reason some OEMs are moving away from offshoring in developing countries involves the need for ESG (environmental social governance) values. As many consumers have made these standards necessary in their purchasing decisions, manufacturers have looked at ways to improve their ESG standing. This includes shrinking their carbon footprint by onshoring manufacturing to truncate supply chains, which also has the added effect of reducing time in transit, shipping costs, and lead times for production.

Onshoring Manufacturing: Competitive Costs & Better Quality

Some of the most frequent issues OEMs have seen with machining from offshore companies include poor accuracy, low levels of durability, lack of stability, and frequent part failures. This has encouraged OEMs in industries that require high-precision parts to source these from more reliable partners. Often, manufacturers need to go to processing facilities to address production issues, which for offshored contracts means the expense of international travel and the added trouble of acquiring visas. This becomes even more difficult when there’s a language barrier and the supplier is a dozen or more time zones away.

While a considerable amount of machining will likely remain in developing countries, much of this is low-end or mid-level. US-based manufacturers have concentrated on more advanced methods of manufacturing that enable domestic machining companies to produce high-quality components at competitive prices. This is due to various technologies that promote automation and data analytics, which are utilized to optimize production. Onshoring manufacturing processes is increasingly seen as a means to obtain high-quality components with tight tolerances for the aerospace, automotive, defense, healthcare, and other industries that require precision parts.

Conflicts, Sanctions & Onshoring Manufacturing

The close relationship between China and Russia, especially after the latter invaded Ukraine, also brought talk of “friend-shoring” by US Treasury Secretary Janet Yellen and others. This involves moving manufacturing connections and reconfiguring logistical nodes to traditionally more friendly and reliable countries. Onshoring manufacturing of high-precision components while friend-shoring others can create win-win situations for OEMs and their partners in production.

While COVID exposed the weaknesses in the global supply chain, Russia’s invasion of Ukraine and the resulting sanctions created a nightmare scenario for those doing business with Chinese partners. China’s close relationship with Russia has already created concerns about sanctioned technology making its way to the Russian military units in Ukraine via China. As a result, sanctions have expanded to several Chinese companies, and there have been claims that Chinese components are finding their way into Russian weapons systems.

Sanctions have expanded to limit this, supported by Ukraine’s allies, including the United States. Onshoring manufacturing will eliminate the chance of OEMs doing business with sanctioned Chinese companies. Yet other concerns exist about sourcing critical parts from China, further encouraging onshoring. Manufacturing in China means potentially doing business with entities involved in committing human rights violations against the ethnic Uyghur population in western China.

Contracting with Staub for Onshoring Manufacturing

While OEMs reestablish relationships with domestic partners to return manufacturing to the United States, companies like Staub Precision Machine continue to innovate. If your company is considering onshoring manufacturing capabilities, Staub will meet and surpass expectations. To minimize risk from incomplete supply chains, consider Staub for contract manufacturing of the highest quality precision parts, with numerous other benefits for our partners.

Staub provides collaborative solutions with our leading-edge equipment and top-notch customer service. To assist with your onshoring manufacturing needs, we use automated processes and a dedicated workforce’s expertise to provide end-use components, finishing, and support services. Staub is a partner manufacturers can count on for high-volume production. To learn more about our capabilities and how we can help with your project, contact the machining experts at Staub today.

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