The Grain Sign Company, based in Cornwall, has long been at the forefront of taking routing machines and software to the limits of their capability to produce arresting commissions
Carving out the future
The simple vinyl cutter is a thing of the past. The routing sector has seen an evolution, with developments in technology that rival any part of the signage industry. The machines on the market now are sophisticated digital cutting systems, capable of accurately matching cut-to-print, and processing a wide range of both flexible and rigid substrates. Yet this evolution happened a while ago. Is it possible that development has stalled in this core sector?
When speaking to key players in the industry, it becomes clear that this is not the case. Across the sector, technological innovations are being applied to existing machinery, improving productivity, user experience, and overall finished quality.
Quality over quantity
One change that has recently affected the industry is an increase in the availability of cheaper, lower-end CNC routers. Many are in agreement that this is making it more accessible for sign-makers of any size to become full service providers. Yet Terry Stafford, managing director of ATA Engineering Processes, exclusive agent for CR Onsrud CNC routers in the UK and Ireland, warns that the cheaper technology on the market may not prove cost effective in the long-run.
ATA Engineering claims that CR Onsrud CNC routers are built to last 10 to 20 years
“There are lots of options for sign-makers when it comes to routing machines,” he explains, “and, like most things in life, you get what you pay for.”
Stafford continues: “We have always taken the view that customers are the best ones to judge which machine suits their purposes best. The CR Onsrud brand of machines are built to last ten to twenty years. They use helical racks, and have done for a number of years; it’s only very recently that the cheaper routers have adopted them.”
When considering these machines as significant investments, their shelf-life becomes an important factor, and one to be taken into account when comparing prices. Stafford does not believe that new technology is the be-all-and-end-all when it comes to choosing a router, asserting: “The basic concept of the three axes machine is still the prime requirement for the industry. There are only two or three vital things needed to achieve a good finish from a router. Firstly, you need a good work holding and a good vacuum system, one that really holds the material down and stops it moving. Secondly, you have to use a heavy, solid machine so that the sample doesn’t vibrate. And of course you need good cutters.
AXYZ’s new super wide-format machines have two heads that move independently of one another, allowing a company to complete two orders at once
“In addition to the CR Onsrud routers, we sell Onsrud cutters, which ensures we can provide a complete package, designed to produce the longest lasting and highest performing machines.”
Reliability and durability are the words that stand out from talking to ATA; adopting the latest innovations appears to take second place to ensuring the quality of the machine’s core components.
Remote controlled service
When it comes to sticking to tried-and-tested technology, a large part of the sector subscribe to ATA’s philosophy.
AXYZ International supplies CNC routers and knife cutting solutions, all designed and built in its factory in Canada. The routers it produces also operate in three axes of motion, affirming the continued industrial relevance of this design. This technology is able to create three dimensional surfaces for moulds or finished products, whilst two axis machines cut shapes from flat materials.
Trotec has released the first laser remote app, which allows the operator to monitor his flatbed laser with an iPhone, iPod touch, or iPad
Yet, while remaining committed to the core elements of this technology, AXYZ does not ignore developments in the market. Instead, they are supplementing their machines with additional software and technical innovations, with the aim of continually improving productivity.
Robert Marshall, vice president of international market development at the firm, explains: “The biggest trends we are committing to at AXYZ are machine control systems and remote interaction from our support divisions. We are now providing online diagnostics for our machines.”
From a customers point of view these machines are important investments and vital to the operation of their company”
He continues: “From a customers point of view these machines are important investments and vital to the operation of their company. If the machines goes down (and, lets face it, all machines do from time-to-time) they want it up and running as soon as possible. These days, rather than sending a technician out on the road, we dial into the machine remotely. It’s much easier and quicker; it enables us to figure out what the problem is, then either send a replacement part or fix it remotely by uploading software.”
In line with guaranteeing maximum productivity, AXYZ also offers a remote training session for machine operators. If a company hires a new member of staff, this system ensures they can be brought up to speed as soon as possible, without the financial and time costs of travel.
Laser technology can engrave intricate
patterns on delicate substrates
Indeed, productivity seems to be the driving force behind all developments at AXYZ. Marshall explains how, once again, the company are adapting existing technology to provide their customers with a more efficient service: “We have developed a range of large, extra wide-format machines. These have two carriages and two heads, which move independently of one another. This allows you to cut out two parts at once, doubling your productivity for only a nominal increase in cost. The only other way of doing this is by buying two machines, which will not only be initially a far more expensive outlay, but which also takes up more floor space.”
He adds: “Our solution doesn’t take up much more space and is only marginally more expensive than a conventional machine.”
In the current economic climate, with many companies competing on price, profit margins are being continually put under pressure. Manufacturers are responding to this. Rather than creating entirely new and (most likely) expensive technologies, they are developing solutions like AXYZ’s super wide-format machines, which allow their customers to produce more material, in less time, for little extra cost.
Laser tech
Although laser technology always sounds futuristic, it has been used for cutting acrylic for years. Recently, however, the market has seen a growing trend in creative finishing, meaning lasers are being called on more and more, and being used on a wider variety of substrates.
Trotec is an international laser manufacturer for engraving and cutting, producing a range of machines from compact CO2 and fiber laser engravers to large-size and industrial laser machines.
Andy Campling, sales manager for Trotec explains the benefits of invest-ing in laser technology: “Trotec laser engraving machines are used for door plates, nameplates, or plaques. Sign-makers can therefore manufacture individual items or smaller series, with the same machine that will produce cost-efficient large series. Virtually any design can be engraved with the laser; with there being no cutting forces, it’s possible to cut or engrave intricate patterns, which a knife or rotating cutter simply couldn’t produce.”
He adds: “Another advantage of Trotec laser systems is that they are as easy to use as a printer, working in your usual graphics or Windows program.”
Virtually any design can be engraved with the laser; with there being no cutting forces, it’s possible to cut or engrave intricate patterns, which a knife or rotating cutter simply couldn’t produce”
Despite the obvious differences between CNC routers and laser cutters, when it comes to trends and technical developments, productivity is once again top priority. There is a particular demand for machines that can provide two services in one application, as Campling explains: “Since we introduced the Vision routers to the UK market we noticed a resurgence of interest in dual mode engravers and routers. The sign market is a mature one now and customers know the strengths and weaknesses of types of equipment. With the VR48 having interchangeable routing and engraving heads we really do have a solution to satisfy both applications.”
The growing trend for creative finishing means lasers are being used on a wider variety of substrates
It is not only the machines them-selves, but the materials used within them that are working harder for the consumer.
“Without a doubt we have a breaking technology in the form of our Ceramicore laser cartridges,” explains Campling, who adds: “We have developed the process of manufacturing laser cart-ridges, engineering out the weak points that eventually cause failure, increasing our already legendary reliability and lowering operating costs to the lowest level ever seen.”
When it comes to technology in the sector, ATA has offered us durability, AXYZ has guaranteed productivity, and now Trotec is paving the way for maximum efficiency. It has released Laser Remote App, which allows an operator to monitor a flatbed laser with an iPhone, iPod touch, or iPad when they are away from the workplace. It is the first iOS app to control a laser plotter, facilitating the overview of current jobs, allowing repositioning of the laser, and providing notifications about possible errors. This application not only helps to avoid production down-times and to reduce the reject rate, but allows the operator to monitor the workflow while out securing deals and winning further business.
One step at a time
Maybe one day, when the storm clouds of the current economic climate have cleared, new ground-breaking and market-changing technology will emerge from the routing sector. Until that time comes, developments in the industry are going to revolve around those key, profit-saving words: durability, productivity, and efficiency. They may not make all the headlines, but these innovations are tightening production lines at a time when margins are slimmest, helping many a sign-maker stay in business and supporting growth in the market, one step at a time.
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