Five-axis milling, turning, grinding, and deep hole drilling – with the traveling column BAZ Leonard Big LBT5.25 from Rema Control, the special machine builder kama is able to make its production even more flexible and efficient through complete machining. This allows it to process a range of parts from a few centimeters to over two meters in length in light and heavy machining.
Special machine builders are indeed special machine manufacturers, as they are constantly faced with changing challenges. This also applies to the company kama in Schönwald, which specializes in custom machines and systems for plastic joining, metal welding, hot riveting, etc. The special machines are primarily used worldwide in the automotive industry. They produce, among other things, interior linings, ventilation ducts, roof trim strips, air channels, as well as plastic parts for sunroofs. The final machining of blow-molded parts such as water tanks or air ducts is also an area that kama machines take on.
However, kama also builds special machines for other industries, such as those used to produce contact films for calculators and remote controls. Even a fully automated production line for vacuum cleaner bags and machines for producing tubes are part of the company's repertoire. Managing director Stefan Magdt explains: "With our many years of experience, we are able to develop and build special machines specifically according to the requirements and wishes of our customers."
High manufacturing depth
Most machine components are manufactured in-house by kama. "Additionally, we take on contract manufacturing orders, provided they are prototypes and small series," mentions Stefan Magdt, "the more demanding, the better." This is due to the well-trained and experienced employees who handle orders from A to Z at kama. They program, operate the machines, and are responsible for ensuring that the quality of the components is right in the end.
"For this, they have a decisive say in the purchase of machines and tools," says Magdt.
The modern machine park leaves little to be desired. It consists of several 5-axis milling machines, CNC lathes, grinding, and erosion technology, allowing the kama production team to process all materials: plastic as well as aluminum, various steels – including special alloys – and titanium.
Highlight in the production hall
With the vertical traveling column BAZ Leonard Big LBT5.25, which will be put into operation in March 2025 by the Italian machine manufacturer Rema Control (see box), Stefan Magdt fulfilled a long-held wish: "We were missing exactly such a machine. In this size, rigidity, and especially with the incredibly many machining possibilities – from five-axis simultaneous milling to turning and grinding to deep hole drilling.
Such flexibility is ideal for us, as we, as a special machine builder and service provider, never know exactly what tasks lie ahead of us."
Finding the right machine was not easy, as there were a few mandatory criteria. For example, the desired machine had to be equipped with a Fanuc control system. "My employees and I are Fanuc fans, which is why all our machining machines are controlled by a Fanuc CNC," emphasizes the managing director.
The second criterion was the machine height. Due to the hall and an overhead crane, the column height is limited. The Z travel must not exceed 1000 mm. The situation is different for the Y travel. This should be as large as possible, greater than 1000 mm, which many machines in this size range cannot offer.
Live demonstration convinces
Ultimately, Stefan Magdt and his specialist worker Jürgen Orschulok for the new machine found what they were looking for at teamtec Werkzeugmaschinen GmbH in Alzenau, the German exclusive representative of Rema Control. The company had been known in-house for years, although there had never been a collaboration until now. "I became aware of teamtec and the Rema Control Leonard Big again on the internet," says Stefan Magdt. This was followed by phone calls and personal meetings.
teamtec sales manager Claudio Lista organized an on-site appointment for the kama team at the Rema plant in Stezzano near Bergamo, combined with a reference visit to a neighboring company that operates with a Leonard Big heavy machining. "There we were able to experience live how stable the machine is built while milling a large cone," mentions machining expert Magdt enthusiastically. "The massive bed and the wide guides prevented any vibrations. After that, I was clear: This machining center fits perfectly for our requirements."
Rema fulfills many special requests
However, for the Leonard Big LBT5.25 to meet Stefan Magdt's and Jürgen Orschulok's expectations 100 percent, Rema Control had to make some adjustments. First and foremost was the replacement of the standard high column of the Big version with the smaller one from the "normal" Leonard, which now fits precisely into the hall.
Rema was also able to fulfill further special requests: The kama version of the Leonard Big features a vertical rotary table embedded in the machine table with a rotary function (B-axis). Additionally, there is a mounted horizontal rotary table (C-axis – also with rotary function), including a manual tailstock. To make this axis "mobile," kama contributed a custom design that allows the table to be easily moved and even completely removed.
An extension of the machine table finally enabled the B-axis table to be positioned in such a way that the entire 2500 mm X travel can be utilized.
Additionally, there was the desired option for using a long boring bar. For this, Rema designed a special boring bar holder that is bolted to the bottom of the Z-axis console. Jürgen Orschulok points out that this addition, while sounding simple, is by no means trivial. The use of the boring bar must be monitored with sensors and activated in the control system to ensure that the machine does not execute incorrect movements and that the boring bar does not, for example, crash into the tool magazine.
Claudio Lista, who has always been available as a contact person for Stefan Magdt and negotiated all special requests with Rema, is convinced: "You can't imagine a machine like this Leonard Big; you have to see it. It has so many additional functions – by the way, also a swiveling milling head and a special grinding cycle, so the implementation in the control was a challenge even for the Fanuc application specialists."
The calculation works out
After a year of experience, Stefan Magdt is very satisfied with his all-round talent: "We manufacture various parts on it, for example, a large 2000 mm long plate with thirty 60 mm holes in H7 fit. Once set, all holes fit." He also mentions small hand-sized parts such as special door hinges made of duplex steel with a 24 percent chromium content. Additionally, he points out the smallest tool that kama has used on the Rema Leonard Big so far: "That was a 0.4 mm drill. Here too, the produced accuracy was perfect."
The managing director is particularly pleased with the reproducible quality and efficiency: "The complete machining on one machine avoids setup errors, so our machining results gain precision. And we save a lot of auxiliary time, which allows us to manufacture significantly more productively in the end."
Thought out down to the last detail
Jürgen Orschulok is enthusiastic about the practical advantages, including the accessibility of the machine: "Thanks to the traveling column principle, I can get very close to the workpiece without having to bend over a guide first."
The maintenance units are also easily accessible, and there is enough space in the rear of the machine to reach the tool changer, energy chains, guide rails, etc. if necessary.
Jürgen Schill, area sales engineer at teamtec, adds further advantages: "The ball screw is stationary; instead, the nut rotates, which avoids vibrations over a length of 2500 mm. Also noteworthy is the traveling tool magazine with its own guide. Furthermore, all energy chains are suspended freely, so they are not exposed to contamination."
Last but not least, he points out the energy efficiency, which is so good due to recuperation during braking, frequency-controlled pumps, and LED lighting that kama received funding from the Free State of Bavaria and the EU for the investment. For company chief Magdt, this is an additional reason for joy.
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