Flex Machine Tools is a relative newcomer to waterjet cutting technology, having introduced its first machine a scant three years ago. That successful launch led the company to a recent partnership with a software company to incorporate some appealing additions to its line of waterjets.
Fifty years ago, Flex Machine Tools had a completely different name and focus: “Midwest Specialties” was a government contractor tasked with developing a better way of tapping holes in metal, which paved the way for the introduction of an innovative tapping arm that would eventually be called FlexArm.
“It was invented out of necessity,” says Nick Kennedy, CEO of Flex Machine Tools. “The tapping arm was showcased at IMTS in 1984, and the FlexArm brand was born.”
The FlexArm line now includes a variety of arms for different applications, including a drilling arm and die grinding arm. In 2017, Flex Machine Tools began building CNC machining centers (FlexCNC) with a monobloc welded steel frame and advanced motion control system. The company also offers the FlexBeam line of profile drilling centers, developed for fast, accurate and economic production of steel profiles.
Along the way, the company experienced huge growth, such as in 2019 when Flex Machine Tools moved into new, state-of-the-art headquarters. By 2021, the company was already running out of space, so it took on a manufacturing expansion of 70,000 sq. ft. to bring the total manufacturing space to 115,000 sq. ft.
Introducing waterjets
The same year the company expanded its manufacturing facilities, its first Flex waterjet machines were introduced. If it weren’t for the perceived inadequacies users experienced in other brands, particularly with service, Flex Machine Tools might not have taken the initiative to develop its own line of waterjets and corresponding service program.
“Before we started selling our waterjet,” says Don Kemper, president of Flex Machine Tools, “we were receiving unsolicited complaints about waterjet service, so we thought if it was done right, we could capitalize on it. We set out to create a new benchmark in waterjets.”
Customers in India, Poland and the United States were among the first to have multi-machine contracts for waterjet systems, ushering in the FlexJet series of waterjets, including the FLX, FL and F Series.
Logan Skelly, national sales manager at Flex Machine Tools, explains that the FLX, which is the most robust machine in the FlexJet line, is for “someone looking for the highest level of performance.” The FL series is more “simplistic, yet a quality machine,” that has traverse speeds of up to 1,400 ipm. The F Series is for “someone who wants a cantilever machine and something more middle of the road.” The F Series is considered a flexible system, delivering speed and precision.
Jet-setting partnership
In April of this year, Flex Machine Tools announced its partnership with IGEMS, a Swedish-based software company, to provide CNC control, CAD/CAM software and hardware to the FlexJet line. IGEMS software is known for its user-friendly interface and powerful features.
Josefin Larsson, CEO of IGEMS, said in a news release that the company has more than 40 years of experience developing CAD/CAM software for the waterjet cutting industry worldwide, and to achieve the best cutting result, IGEMS began developing its own CNC controller six years ago.
“With Flex Machine Tools’ skill in producing cutting machines and IGEMS’ software knowledge,” Larsson said, “together we’ll bring the most capable solution to market, saving time and creating profitable partnerships for end users.”
Kemper said in the same release that the partnership with IGEMS and its “exceptional software,” allows Flex Machine Tools to set a new “benchmark for precision, efficiency and reliability in waterjet cutting technology.”
Tools of the trade
IGEMS offers software and hardware that work with the FlexJet machines, including the advanced Tilter 5-axis waterjet cutting head, which Skelly says is the “fastest, most accurate kinematic solution for bevels up to 45 degrees.” Furthermore, the Tilter head includes an auto stand-off, which maintains a consistent distance between the cutting head nozzle and the top of the surface of the material being cut.
IGEMS also brings the Snapper camera, used for optimal positioning. The camera system was designed specifically for waterjets, offering a user-friendly method for providing the “basis for optimal positioning in the numeric control program, saving time and minimizing material use.”
FlexJet users also benefit from the IGEMS Rounder kinematic compensation tool, which is designed to enhance the accuracy of the 5-axis cutting machines. Skelly says it “maintains perfect alignment of the cutting head throughout its range of motion, ensuring precise calibration for exact cutting.” The technology also accounts for mechanical deviation by measuring multiple positions on the bevel, making calibration a breeze.
“The traditional 5-axis head calibration requires a technician’s visit, leading to downtime and increased cost,” Skelly says. “Our new Rounder solution allows you to calibrate it yourself in just 15 min.”
The Straighter Perpendicular Calibrator is a precision tool designed to efficiently calibrate the perpendicularity of 5-axis waterjet cutting heads. Its streamlined process reduces setup time and eliminates the need for complex dial gauge setups, ensuring accurate and consistent alignment.
“The Straighter is an excellent tool for quality control,” Skelly says, “producing a smoother, more streamlined cutting path.”
Overall, the release stated that the partnership is producing improvements designed to “cater to the intricate needs of diverse materials and cutting requirements, ensuring unparalleled accuracy and efficiency in waterjet cutting processes.”
Service upgrades
Downtime is a budget killer as much as it is a productivity killer. Whether it’s a bottleneck due to a slight machine malfunction or a complete shutdown due to a broken part that needs to be replaced, waterjet users can be plagued with service issues unless they are using machines from manufacturers that have the infrastructure in place to quickly serve them.
With Flex Machine Tools’ 24/7 remote technician support, service technicians dispatch within 48 hours and 100 percent of spare and replacement parts are in inventory. Next-business day shipping of parts ensures the company has its customers covered.
“The commitment to exceed customer expectations is one of our core values,” Andrew Schaefer, Service Manager at Flex Machine Tools says. “We want to go above and beyond to make our customers happy, and we do this by delivering exceptional customer service.”
The ratio of technicians to FlexJet machines on the market, he says, is 1 to 15, which allows Flex Machine Tools to maintain strong relationships with customers. At Flex, Schaefer says, striving for resolution commitment is a mindset.
“We’re not looking for problems,” he says, “we’re looking for solutions. We ensure that we fix the problem properly and thoroughly.”
