En Route to Success
Simply put, CNC routing equipment, and its accompanying software, saves sign-makers a huge amount of time when it comes to producing all sorts of signage work. Whether this is small wayfinding boards or large-scale pieces, this kit takes away many of the manual parts of sign-making.
Add in the fact that CNC routers and software will almost certainly give you a higher quality of finish, not to mention pinpoint accuracy, and it is easy to see why the popularity of this technology has exploded in the sign industry in recent years.
With this in mind, we speak with a number of specialist providers in the market to find out more about their latest developments and how integrating these products as part of your production line-up will help you strengthen your offering for customers.
Rigidity and Reliability
AXYZ operates under the tagline ‘Tailored Routing Solutions’, working with a wide range of customers to help them bolster accuracy in their work. Product manager Kevin Recinos explains that for sign-makers, quality CNC kit and software will allow them to achieve speed and reliability to process the various materials used in signage applications.
“Sign-makers focusing on exterior signs such as those you would see in retail spaces will process tough materials such as non-ferrous metal sheets, thick acrylic, or aluminium composites,” Recinos says.
“Now, any router configured to run slow enough with the right cutters will be able to process these materials. The problem many sign-makers run into is how rigid and well-equipped their CNC machines are to process materials at high speeds.
“Depending on the number of projects a sign-maker may be working on, the CNC machine may be finished cutting all the materials by midday or perhaps the next day.
"The productivity of a machine will come down to how fast can you cut parts, the quality of the product, and the time involved to get your products to the end-user. Taking into consideration rigidity, reliability and performance should be at the top of the list.”
Recinos goes on to say that upgrading a CNC machine can unlock a “tremendous” amount of additional value. He explains users may be looking for greater rigidity or modern software that will help improve their production speed or product quality.
Given the amount of digital transformation over the past two decades, sometimes an upgrade may be necessary to reduce the learning curve of new operators.
We’ve seen more and more customers process different types of materials – often more rigid such
as plywood and non-ferrous metals”
“We’ve seen more and more customers process different types of materials – often more rigid such as plywood and non-ferrous metals,” Recinos says, adding: “Many low power CNC routers or fast knife cutting machines do not have the rigidity to process these tougher materials at production level speeds.”
Recinos says the Trident machine from AXYZ remains its best overall solution, designed to process more than 500 different materials ranging from zinc to corrugated cardboard.
AXYZ says its Trident machine remains its best overall solution
“We’ve seen more use cases for longer-format machines where a 16” machine may be split into two sections to run continuous operations,” he explains.
“While an operator loads or unloads material on one side; on the opposite end, you have the machine cutting fresh new material essentially doubling production. “
For sign-makers that are more focused on processing non-ferrous metals and plastics, Recinos says METALWorker products bring to the table higher performance, an exceptional user interface, and greater cut quality.”
Plan for the Future
Software next and SAi specialises in solutions for CNC routing, primarily with its EnRoute products.
Philippe Meyer, product manager for EnRoute Software at SAi, urges sign-makers to look for CNC kit, tools, and software that can handle the work they do today, but also provide flexibility to grow and expand into different types of signs in the future.
SAi’s latest EnRoute software has support for profile tools, both in simulations as well as in the tool pathing
“Sign-makers need a machine that can handle the materials that they intend to route with accuracy,” Meyer explains.
“While the tools also depend on the materials to some extent, in general, a standard kit of end mills, ball nose mills, conic tools, and engraving bits will provide them with a wide range of capabilities.
“When considering software packages, sign-makers should opt for a total-solution software that can design, toolpath, and output.
"The best software will be able to do 3D designing and handle third party files as well as generate the tooling for it.
"A software package like SAi EnRoute can do this, as well as provide additional functionality for other types of jobs.
“In addition, a software program should have driver support for different CNC machines. Should they want to expand their business into another field or take on jobs that are outside of the classical sign-making business from time to time, EnRoute software can handle those as well.”
While Meyer says sign-makers should consider upgrading to gain access to the newest features of the software and to maintain their level of support, with SAi’s subscription model, upgrades are no longer necessary as customers will always have access to the latest released version, and the support that goes along with it.
O Factoid: SAi’s subscription model means upgrades are no longer necessary as customers have access to the latest released version and the support that goes along with it O
As for the latest developments at SAi, Meyer highlights EnRoute’s Rapid Texture and parametric texture options, which he says continue to be popular with sign-makers for creating unique custom designs. A new ‘Peeled Pole’ texture has also been added to the texture library.
In the latest version of EnRoute software, SAi has added support for profile tools, both in simulations as well as in the tool pathing.
“Our Corner Fine strategy will allow you to add an additional finer ball nose that will automatically clean up the inside corners according to the profile tool that was used, giving your signs a classic finish,” Meyer says.
“Also notable are the new No-Lift tool pathing to save time between passes while routing and new vectorisation options like colour and centreline vectorisation, which make it easier to turn images into contours.
"We’ve also added the setup manager tool, which allows you to fully customise your EnRoute interface so that all tools are exactly where you need them to be for your workflow.”
Meyer also adds: “Support and training are important but often overlooked considerations when selecting your CNC software. EnRoute subscription plans include ongoing technical support via phone or email. SAi also offers a variety of training options so you can get the most from your software.”
Higher Speeds and Quality
Elsewhere and as its name may suggest, LKH Tools offers CNC machine and routing tools as well as consultancy, software, and training. Liam Hodson, tooling and machine consultant, explains price can often lead to sign-makers facing a battle of inconsistency in this market.
“There is a temptation to purely purchase a routing tool on cost without looking or seeing the hidden benefits that the higher quality routing tool will give them,” Hodson says, adding: “The cheaper option may seem to give them a better return on paper but when you add the cost of re-cutting parts or re-working the cut edge, the perceived benefit is soon lost and inevitably costs more.
“LKH Tools is a UK distributor for Crown Norge tools manufactured in Switzerland. Using high quality European grade carbide and manufactured on the latest grinding machines, the high consistency and quality is maintained so that each tool meets the same high standards required.
“For the customer, they have the security that each tool will cut the material correctly, cleanly, and efficiently. Higher cut speeds, vastly improved quality of cut, tool life, and removing the need for any additional finishing are to be expected when using these tools.”
Hodson goes on to say that using one tool to cut all materials with different thicknesses is often the reason why the cut quality is poor and tools do not last as long as they should. To combat this, LKH offers a programme of tools that are designed for each material type. In addition to this, they are also matched in length to the common material thickness.
“Using a very long tool on thin material will create tool chatter and vibration which inevitably produces a poor result and damages the tool,” Hodson explains, adding: “A higher quality tool will not only cut better but will be kinder to the machine.
“Routing spindles will struggle to cut materials with a worn, damaged, or poorly ground tool. In some cases, a low-quality routing tool will also not be correctly balanced and can lead to spindle damage or failure when used over a prolonged period of time.”
LKH says its MP Superior and MP DLC coated range reduces the heat build-up and friction when routing aluminium
In recent years, LKH has introduced coated tools for dry routing aluminium that eliminates the need for coolant or oil.
Hodson says the MP Superior and MP DLC coated range reduces the heat build-up and friction when routing aluminium.
As a result, he says cutting speeds and quality are significantly increased and customers can swap between material types, without the need to clean down the machine between cuts.
In addition to this, LKH introduced Gen2 acrylic tools for cutting and polishing clear acrylic, offering the ability to cut up to 10mm thick acrylic in one pass, without the need for a finishing cut has changed many sign-makers’ production.
LKH’s new Gen2 acrylic tools for cutting and polishing clear acrylic offer the ability to cut up to 10mm thick acrylic in one pass
“By removing the need for any further hand finishing or flame polishing in most cases, it simplifies what would have been normally a labour-intensive process,” Hodson says.
He concludes: “Router tooling has had significant advancement in design and coatings in recent years giving the sign-maker a much wider choice of materials to use on the CNC router.
"These include harder wearing and historically, more difficult to cut materials such as high-pressure laminates and fire-resistant materials.
“Our range of tools such as the MP Superior coated tools allows for these to be routed as cost effectively as plastics and woods for example. The more typical materials such as plastics, PVC, ACM, woods, aluminium, and other non-ferrous metals can be processed faster and with a better cut edge than in comparison to lower quality tooling.”
The benefits of working with CNC equipment and software are clear to see, as are the reasons to upgrade this kit and ensure you are taking advantage of the latest tech in the market. Only with new investment and upgrades can you ensure the highest levels of accuracy and performance.
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