Precision Machining

Machining Dynamics and Process Stability
Samuel Milton, Sirris

Unstable conditions such as chatter not only reduce part quality but also lead to increased tool wear, machine downtime, and production costs. By analysing the interaction between cutting forces, vibrations, and machine structure, we can better predict and prevent instabilities. The session will highlight proven strategies—such as dynamic modelling and process optimization—that enhance machining performance, improve productivity, and extend tool and machine life on the shop floor.

Embracing the future: Digital manufacturing and the fast-evolving CNC machining landscape
Dominiek Reynaerts, FlandersMake@KULeuven

Digital manufacturing is revolutionizing the production environment at an unprecedented pace by leveraging data to drive manufacturing processes. In this talk, we present real-time in-process quality control (<10 µm) and process monitoring using additional sensors on machine tools. This not only reduces quality control efforts but also improves machine utility. With lessons learned from digital twins, we now optimize tool paths using realistic simulations before a single chip is cut. Further up the process chain, we are shortening the CAD-CAM chain by harnessing AI for automated tool path generation. This allows designers to understand the limits and possibilities of subsequent manufacturing. By leveraging these technologies, we create more autonomous, decentralized, yet responsive manufacturing systems, enhance manufacturing cost evaluation support for designers, and streamline the design-to-production process.

Precision Machining of Optics for Space
Michael Vervaeke, FlandersMake@VUB

The fabrication of optical components needs precision levels several orders of magnitude higher than those required in conventional machining processes. In space and astronomical instrumentation, these requirements become increasingly stringent, demanding specialized workflows closely integrated with advanced metrology. In this context, we present the optical manufacturing workflow developed for the ESA EnVision mission to Venus, specifically for the production of multiple optical components for the VenSpec-H instrument.
Additionally, we address the stringent specifications outlined by the Einstein Telescope Pathfinder facility at Maastricht University (UMaastricht), particularly in relation to the development of the main interferometer mirrors. These mirrors are being fabricated as part of a risk mitigation initiative in preparation for the 10-kilometer baseline Einstein Telescope. The precision requirements for such components are comparable to those encountered in cutting-edge applications such as extreme ultraviolet (XUV) lithography.

Process thinking in precision manufacturing enables highest quality at lowest cost
Jurgen Adriaensen, Absolem Engineers

It is very easy to design an expensive product. By adding unattainable tolerances, excessive surface finish requirements, and extreme cleanliness levels, you can ensure that the product will never be manufactured cost-effectively. These high-end specifications often arise from risk mitigation efforts, a false sense of safety, a lack of understanding of the cost implications of certain tolerances, or an attempt to capture physical requirements in a mechanical drawing. Especially when processing technology bridges the gap between incoming components and the final product, things can become quite unclear. To design effectively, understand the physics, identify the physical limits, and align your design and process technology with them. Otherwise, you'll spend the product’s entire life fighting physics—and spoiler alert: physics always wins.

Data-Driven Optimization of Machining Processes
Peter Ten Haaf, Sirris

In the machining industry, adaptive machining is often referred to as taking targeted actions based on the current production situation. The successful application stands or falls with having correct (real-time) data on the one hand and the corresponding structured and digitized working methods on the other. The first is coming more and more within reach thanks to the ever-growing supply of hardware and software. For the second, one must take the step to “model-based machining,” where parameterized models (formulas) are used to identify the optimal machining process.

Electro-physical and chemical machining & metrology
Sylvie Castagne, FlandersMake@KULeuven

Most recent research developments in non-traditional precision manufacturing and metrology as well as their applications are introduced in this session. The talk is divided into 3 parts: 

1. EDM-ECM processes, including hybrid laser-ECM processing of novel materials, on-machine metrology and data-driven pulse analysis in micro-EDM for mould making applications, sequential wire-EDM&ECM for the aerospace industry, and electrochemical layered micromanufacturing towards integrated sensing; 
2. Laser micromachining, including selective laser ablation and ultrafast laser surface patterning for medical, tooling, sensing and energy applications, and in-process monitoring of laser ablation; and
3. Measurement technologies, including optimization for optical and tactile 3D metrology, and traceability and in-line quality control with xCT for industrial applications such as AMed parts and batteries. 

Automating Quality Inspection
Sina Ditzel, Flanders Make

Ensuring optimal quality in custom manufacturing requires advanced, integrated quality control to perform geometrical analysis, detect deviations, and identify defects. In this talk, we present innovative and smart inspection and monitoring systems, with a focus on optical methods, including cameras, structured light and laser scanners. One example is the automation of 3D scanning using our marker less scanning algorithm. This system addresses the challenge of slow, labour-intensive inspection of custom products by combining viewpoint optimization with marker less point cloud registration. The result is a significant reduction in scan time and manual setup