As product miniaturization continues, micromachining continues to make inroads into the manufacturing industry. CTE will once again provide a special section about micromachining in our May issue.

At the other end of the size spectrum, I've noticed more developments in large-part machining. Coincidentally, our April issue will include a focus on that topic. As part of our planned coverage, I visited Coldwater (Ohio) Machine Co. and will present a profile about the shop's expertise in producing short runs of massive components, many of which are for the special machines CMC builds.

Prior to visiting Coldwater, I had the opportunity to drop by the production facility for FlexArm Inc./FlexDrill CNC in Wapakoneta, Ohio. While there, I saw an example of FlexDrill's GRD-series gantry machining center. The 3-axis CNC machine has an X-axis up to 30' (9.1m) and a 4' (1.2m) or 6' (1.8m) Y-axis, enabling long parts to be processed in one setup.

When it comes to machining large parts, getting it "done in one" is a huge benefit. A single setup not only avoids the dimensional-tolerance stack-up and setup errors that can occur but minimizes movement of cumbersome workpieces.

Turning to the current issue, the Industry Briefs section includes a report about the new Emco Mecof Powermill 5-axis vertical machining center at Baker Industries Inc., Macomb, Mich.

Large enough to hold two semitrailers on its platform, the machine enables Baker Industries to produce colossal components—up to 16m (52.5') or larger—such as assembly and bond jigs for the aerospace industry. The Powermill lets Baker perform everything from roughing to finishing on one machine.

Of course, when going large, the investment in time and money is also grand. Baker Industries reports that the 11-month construction and build project for the Powermill cost $3.4 million.

For another large gantry mill—this one built by Fives Liné Machines Inc. (CTE covered this in the February issue's Productive Times section)—Sonaca Montreal Inc., Mirabel, Quebec, wouldn't divulge the cost. Nonetheless, it was pricey enough that short-term loans provided by the Canadian and Quebec governments supported the purchase of the 5-axis vertical gantry mill, which can machine parts up to 70' (21.3m) long and 10' (3.05m) wide.

I expect to hear more about megamachines coming online as the quest continues—particularly among aerospace OEMs—to machine more massive, monolithic structures to reduce assembly. Doing so will reduce costs and strengthen the final product.