KERN Micro Platform

KERN Micro HD

KERN Micro HD

Description Technologies Industries Specifications

Highest productivity without limits

The KERN Micro HD is the solution for high-precision serial – and prototype – production and when the ques-tion comes up whether production is still possible.
This system is based on the second generation of KERN Micro, which was launched in 2019, and relies on proven, high-quality KERN technology. It provides absolute reliability and stability over a long machine life.

– Compact design and small footprint of less than  54 sqft/5 qm

– Supreme machine stability with advanced  KERN temperature management

– High dynamics and productivity through integrated linear motor drives

– Best quality and wear-free due to innovative KERN micro-gap hydrostatics

– Multi-shift operation with no need for operator with integrated changer for up to 210 tools and a maximum of 60 workpieces

– Certified interfaces for additional accessories and automation systems

– Management and maintenance during operation without interruption while machine is running

The new standard in precision manufacturing

With the newly developed micro-gap hydrostatics, the linear drives and the advanced KERN temperature management, the KERN Micro HD is the new benchmark in precision, long-term stability and dynamics. Together with the know-how of our customers and the KERN application technology, the KERN Micro HD is unmatched.

– Largest possible pivoting range on floor area less than 54 sqft/5 qm

Product design

When designing our machines, we take into account all aspects of automated serial production — from automatic tool change to ergonomics at each access point.
Tool change
For fast and safe tool changes during serial production runs, all KERN machines provide the ability to load the tool magazine during machining. A large number of tool slots allows long periods of autonomic operation; the tools are optimal and clearly arranged. The quick-change system of the KERN Micro is patented.
Ergonomics
The optimal accessibility and clamping height of every KERN machine ensures ergonomic working. The work space is bright, easily visible and accessible at all times by a main door – even with the machine running under automation.
Axle kinematics
KERN machines are designed with optimized axle kinematics in order to minimize travel ranges, especially for small, 5-axis parts. Highly economical linear axes and generous tilt and rotational axes, combined with their optimized spatial arrangement, enable complicated free-form geometries to be machined with the lowest possible travel ranges, in a single clamping.
Patented machine stands
The symmetrical, gantry design of KERN machines with a machine stand made from KERN Amorith (mineral casting, reinforced with heavy steel struts) suppresses virtually all oscillations by virtue of its weight and patented material.

– Tool cabinet with quick-change plates for over 210 tools

Product design

When designing our machines, we take into account all aspects of automated serial production — from automatic tool change to ergonomics at each access point.
Tool change
For fast and safe tool changes during serial production runs, all KERN machines provide the ability to load the tool magazine during machining. A large number of tool slots allows long periods of autonomic operation; the tools are optimal and clearly arranged. The quick-change system of the KERN Micro is patented.
Ergonomics
The optimal accessibility and clamping height of every KERN machine ensures ergonomic working. The work space is bright, easily visible and accessible at all times by a main door – even with the machine running under automation.
Axle kinematics
KERN machines are designed with optimized axle kinematics in order to minimize travel ranges, especially for small, 5-axis parts. Highly economical linear axes and generous tilt and rotational axes, combined with their optimized spatial arrangement, enable complicated free-form geometries to be machined with the lowest possible travel ranges, in a single clamping.
Patented machine stands
The symmetrical, gantry design of KERN machines with a machine stand made from KERN Amorith (mineral casting, reinforced with heavy steel struts) suppresses virtually all oscillations by virtue of its weight and patented material.

– Interfaces for all commercial automation

Automation

KERN CNC machining centers have standardized interfaces for all common automation systems. With the ability of a KERN to be integrated into any existing production system, our machines offer maximum flexibility and security for your automation tasks.

The automation of a KERN machine does not interrupt servicing work, since the main door to the machinery area remains constantly accessible.

KERN Evo manufacturing cell ER6
KERN Micro: Integrated workpiece changer
KERN Micro: Video integrated workpiece changer

Automation
KERN CNC machining centers have standardized interfaces for all common automation systems. With the ability of a KERN to be integrated into any existing production system, our machines offer maximum flexibility and security for your automation tasks.

The automation of a KERN machine does not interrupt servicing work, since the main door to the machinery area remains constantly accessible.

Your advantage:

  • Unmanned, stable serial production, 7 days per week
  • Increase of turn over through unmanned night shifts
  • Operating of multiple machine tools through only one user
  • Now, with the KERN Micro’s new  integrated workpiece changer, you too can easily enter the world of automation.

Your benefits:

  • Deploy unmanned shifts (nights & weekends)
  • Pays for itself in under 12 months
  • No additional set-up space needed
  • No additional software or interfaces needed
  • Exploit the high process stability of the KERN Micro

– Intelligent thermal management for optimal temperature regulation of all machine components

Temperature stability

KERN Microtechnik has developed a sophisticated thermal management system for its machining centers which is perfectly matched to the requirements of each KERN machine.

Due to proprietary software algorithms the heat is dissipated in a controlled manner at the places where the temperature is produced. That’s the reason why KERN machines achieve an extremely high temperature stability – without influencing the indoor climate.

By drastically reducing the thermal sources of error, this intelligent control of the complete machine periphery, including the cooling lubricants, is one of the basis for our KERN potential.

Your benefits:

  • Constant zero and kinematic points for almost unlimited periods
  • Significant higher process stability results in significantly reduced quality assurance costs
  • Payback on your investment costs due to high energy efficiency

– Perfect ergonomics with full access to the working space as well as free access to the mounting area

Product design

When designing our machines, we take into account all aspects of automated serial production — from automatic tool change to ergonomics at each access point.
Tool change
For fast and safe tool changes during serial production runs, all KERN machines provide the ability to load the tool magazine during machining. A large number of tool slots allows long periods of autonomic operation; the tools are optimal and clearly arranged. The quick-change system of the KERN Micro is patented.
Ergonomics
The optimal accessibility and clamping height of every KERN machine ensures ergonomic working. The work space is bright, easily visible and accessible at all times by a main door – even with the machine running under automation.
Axle kinematics
KERN machines are designed with optimized axle kinematics in order to minimize travel ranges, especially for small, 5-axis parts. Highly economical linear axes and generous tilt and rotational axes, combined with their optimized spatial arrangement, enable complicated free-form geometries to be machined with the lowest possible travel ranges, in a single clamping.
Patented machine stands
The symmetrical, gantry design of KERN machines with a machine stand made from KERN Amorith (mineral casting, reinforced with heavy steel struts) suppresses virtually all oscillations by virtue of its weight and patented material.

– One-box design

Product design

When designing our machines, we take into account all aspects of automated serial production — from automatic tool change to ergonomics at each access point.
Tool change
For fast and safe tool changes during serial production runs, all KERN machines provide the ability to load the tool magazine during machining. A large number of tool slots allows long periods of autonomic operation; the tools are optimal and clearly arranged. The quick-change system of the KERN Micro is patented.
Ergonomics
The optimal accessibility and clamping height of every KERN machine ensures ergonomic working. The work space is bright, easily visible and accessible at all times by a main door – even with the machine running under automation.
Axle kinematics
KERN machines are designed with optimized axle kinematics in order to minimize travel ranges, especially for small, 5-axis parts. Highly economical linear axes and generous tilt and rotational axes, combined with their optimized spatial arrangement, enable complicated free-form geometries to be machined with the lowest possible travel ranges, in a single clamping.
Patented machine stands
The symmetrical, gantry design of KERN machines with a machine stand made from KERN Amorith (mineral casting, reinforced with heavy steel struts) suppresses virtually all oscillations by virtue of its weight and patented material.

When productivity and precision really count

The KERN Micro is ideal for all industries requiring ultra-high precision in serial production.

– Tool/mold production

High precision and stable operation for both direct and electrode milling

Tool, mold and manufacture

In microtechnology, manufacturers of shaping and cutting dies and molds are often tasked with precise machining of very hard materials. All CNC Machining centers by KERN Microtechnik are perfectly suited to the direct milling of hardened steels or even carbide as well as milling with copper, tungsten copper and graphite electrodes.

Direct hard milling with KERN — your benefits

  • High quality surface finish due to HSC spindles with maximal smoothness, hydrostatic pivots and perfect contour control via iTNC530 or TNC 640
  • Milling of free-form surfaces with high precision through μ-exact spindle movements and 5-axis simultaneous milling
  • Very high absolute accuracy thanks to perfect calibration between tool and workpiece in all KERN machines
  • Short set-up times for small production batches

Electrode milling with KERN — your benefits

  • Very high absolute accuracy as a basis for stable EDM processes
  • High quality surface finish due to HSC spindles with maximal smoothness, hydrostatic pivots and perfect contour control via iTNC530 or TNC 640
  • Extremely high repeat accuracy: thanks to perfect thermal management every KERN machine enables absolutely stable unmanned serial production (using proprietary technologies)

– Automotive

Ideal for flexible production of part families through modular programming in coordination with the CIP

Automotive

The KERN Micro and KERN Evo CNC machining centers by KERN Microtechnik are a supreme match for the extraordinarily high expectations and requirements which the automotive industry places on serial production machines. KERN machines distinguish themselves by exceeding the highest quality standards and delivering extreme process stability and reliability — while being specifically optimized for unmanned, 24/7 production.

KERN machines are especially well suited to meeting the following requirements of the automotive industry:

  • Short set-up times due to modular programming for flexible production of entire families of parts
  • Integrated measuring technology for maximum part reliability
  • Professional service availability
  • Permanent process optimization in close coordination with the customer-specific Continuous Improvement Process (CIP)

– Dental equipment

Universal applications for manufacturing complex geometric shapes from a variety of very hard materials

Dental equipment

Dental technology products, for example dental prostheses, require precision machines capable of rapidly milling highly varying workpieces made from very hard materials like titanium and ceramics. Dental prostheses are frequently made and fitted for the patient on the same day, placing especially high demands for reliability and flexibility on the CNC machining center being used.

KERN Microtechnik possesses long-standing experience of the dental industry’s unique requirements. With the KERN Micro KERN Microtechnik has developed a universal machine capable of not only processing the widest range of very hard materials, but also of fast and precise milling of complex geometric forms. Thanks to extensive automation and short processing times, KERN Micro offers the dental industry sustained precision during continuous operation.

Overview of the advantages for the dental industry:

  • Maximum vibration control enables optimal tool life
  • Fewer compensatory movements and reduced processing times due to optimized kinematics
  • 5-axis machining with optimal accessibility and pressure angles
  • Reduced maintenance thanks to intelligent chip flow
  • Comprehensive automation possibilities

– Medical equipment

For complex geometries using high grade materials like titanium, chromium, stainless steel, ceramics or specialized plastics

Medical equipment

Medical products, e.g. precision components in surgical instruments, are manufactured from premium, hard to process materials like titanium, chromium cobalt, stainless steel, ceramics or especially hard plastics (e.g. PEEK or polyacetal). Their ability to be easily and hygienically cleaned is particularly important, making the quality requirements correspondingly high for CNC machining centers used for the serial production of medical equipment.

With the Micro CNC machining center KERN Microtechnik has developed a machine that superbly meets all of the medical industry’s criteria for supreme surface finish quality and geometric precision.

Overview of the advantages for the medical industry:

  • Maximum vibration control enables optimal tool life
  • Fewer compensatory movements and reduced processing times due to optimized kinematics
  • 5-axis machining with optimal accessibility and pressure angles
  • Reduced maintenance thanks to intelligent chip flow

– Micromechanics and the watch industry

Fulfilling the highest demand for (free-form) geometries, precision, repeat accuracy after tool changes, and surface finish

Micromechanics and the watch industry

Micromechanics — the production of microscopically small components — requires high volumes of precision-milled parts. Our KERN Evo and KERN Micro machines are not only optimized for automated high speed manufacturing of watch plates and watch parts, but also for lightguide connection elements, medical endoscope heads and turbine wheels in the submillimeter range.

In close collaboration with a wide range of watchmakers, the performance of KERN’s high precision machining centers has been perfected right from the start. For many years, KERN machining centers have met the exacting demands of these industries for (free-form) geometric complexity, precision and surface finish, setting new standards for machining capabilities in the microtechnology sector.

The advantages of KERN machines for the microtechnology sector:

Intelligent chip management can be engaged for thorough cleaning and recycling of valuable materials

μ-exact probing allows maximum repeat accuracy during tool changes in processes with more than one clamping

Maximum process reliability ensures uniform quality and guarantees minimal waste

  • Intelligent chip management can be engaged for thorough cleaning and recycling of valuable materials
  • μ-exact probing allows maximum repeat accuracy during tool changes in processes with more than one clamping
  • Maximum process reliability ensures uniform quality and guarantees minimal waste

– Research and development

Widely employable across a vast range of high-tech research fields

Research and development

Our machines are making valuable contributions to high level research projects in internationally renowned scientific institutions throughout Europe, Asia, USA, Brazil, Cuba and South Africa. Whether with KERN machines at our customers’ sites or at KERN’s contract production plant in Eschenlohe — KERN Microtechnik is an active development partner for high precision parts across a vast range of technologies and research fields:

  • Research in satellite technology
  • Nuclear fusion research (e.g. UK and USA)
  • Neurosurgery
  • Processing of hard to machine materials (high-alloy steel, titanium, sandwich materials)
  • CERN particle accelerator (Switzerland)

All KERN machines offer the following advantages for research and development applications:

  • Maximum precision through absolute positional accuracy and perfect temperature control
  • Maximum reliability and adherence to all industry standards guaranteeing low maintenance and servicing requirements

Axes: travel

  • X-axis350 mm
  • Y-axis220 mm
  • Z-axis250 mm
  • B-axis-110° to +110° option -180° to +110°
  • C-axis360° endless

Axes: dynamics

  • vmax X, Y, Z60 m/min
  • amax X10 m/s²
  • amax Y15 m/s²
  • amax Z20 m/s²
  • vmax B100 1/min
  • vmax C200 1/min
  • full load torque B648 Nm
  • constant torque B360 Nm
  • holding torque B-axis (clamped)300 Nm
  • full load torque C135 Nm
  • constant torque C75 Nm

Automatic tool changer HSK 25

  • 20 positions, 101 positions, 209 positions
  • max. tool diameter for automatic tool change70 mm (each 2nd tool rack position not in use)
  • max. tool length for automatic tool change including tool holder 150 mm

Automatic tool changer HSK 40

  • 18 positions , 90 positions, 186 positions
  • tool changing time< 3 s
  • chip to chip time< 4,5 s
  • max. tool diameter for automatic tool change70 mm (each 2nd tool rack position not in use)
  • max. tool length for automatic tool change including tool holder 150 mm

Numeric control

  • Heidenhain TNC640

Spindle HSK 25

  • nmax30.000 1/min
  • nmax(optional)50.000 1/min
  • full load torquemax (S1)1,6 Nm
  • powermax (S1)6 kW

Spindle HSK 40

  • nmax42.000 1/min
  • full load torquemax (S1)5,9 Nm
  • powermax (S1)15 kW

Clamping System on 5th axis

  • Erowa ITS 148
  • System 3R Magnum

KERN Micro Vario

Description Technologies Industries Specifications

Compact, extremely precise, incredibly powerful

With its new design and advanced developments, the second generation of the KERN Micro sets new standards in flexibility, precision and productivity. Ultra-compact, trimmed for productivity and precision, flexible and application-oriented, the KERN Micro Vario generates the decisive competitive advantage – permanently and efficiently.

– Compact design and small footprint of only  4 qm /43 sqft

–  Supreme machine stability with the advanced KERN Temperature Management

– High productivity with unmatched accuracy

– Best quality, flexibility and competitiveness

– Multi-shift operation with no need for operator with integrated changer for up to 210 tools and a maximum of 60 workpieces

– Certified interfaces for additional accessories and automation systems

– Management and maintenance during operation without interruption while machine is running

Flexible platform for highest demands

With the sophisticated machine design, the unique KERN temperature management and the high-end components, the machine reliably delivers the well-known KERN precision and repeatability. The KERN Micro Vario is at home in the industrial environment. It is reliable, robust and durable – for every kind of application. Special editions for the perfect machining of graphite or for zirconia machining are also available on the basis of  a KERN Micro Vario.

– Production with minimal positional variance due to a positional accuracy of ± 1 μm

Minimal position deviation

The position accuracy of KERN Machines according to VDI/DGQ 3441 is legendary. Each machine is laser-measured to guarantee precise positions down to the μ — from the first to the 10,000th workpiece during unmanned serial production.

Position deviation KERN Micro: Pa = ± 0.5 μm
Position deviation KERN Evo: Pa = ± 0.5 μm
Position deviation KERN Pyramid Nano: Pa = ± 0.3 μm

Your advantage:

  • Maximum machining precision on the workpiece
  • Extremely stable processes through reliable repeatability
  • Reduced quality assurance costs
  • Reduced scrap parts

– Largest possible pivoting range on a 4 sq. m floor area

Product design

When designing our machines, we take into account all aspects of automated serial production — from automatic tool change to ergonomics at each access point.

Tool change

For fast and safe tool changes during serial production runs, all KERN machines provide the ability to load the tool magazine during machining. A large number of tool slots allows long periods of autonomic operation; the tools are optimal and clearly arranged. The quick-change system of the KERN Micro is patented.

Ergonomics

The optimal accessibility and clamping height of every KERN machine ensures ergonomic working. The work space is bright, easily visible and accessible at all times by a main door – even with the machine running under automation.

Axle kinematics

KERN machines are designed with optimized axle kinematics in order to minimize travel ranges, especially for small, 5-axis parts. Highly economical linear axes and generous tilt and rotational axes, combined with their optimized spatial arrangement, enable complicated free-form geometries to be machined with the lowest possible travel ranges, in a single clamping.

Patented machine stands

The symmetrical, gantry design of KERN machines with a machine stand made from KERN Amorith (mineral casting, reinforced with heavy steel struts) suppresses virtually all oscillations by virtue of its weight and patented material.

– Tool cabinet with quick-change plates for over 200 tools

Product design

When designing our machines, we take into account all aspects of automated serial production — from automatic tool change to ergonomics at each access point.

Tool change

For fast and safe tool changes during serial production runs, all KERN machines provide the ability to load the tool magazine during machining. A large number of tool slots allows long periods of autonomic operation; the tools are optimal and clearly arranged. The quick-change system of the KERN Micro is patented.

Ergonomics

The optimal accessibility and clamping height of every KERN machine ensures ergonomic working. The work space is bright, easily visible and accessible at all times by a main door – even with the machine running under automation.

Axle kinematics

KERN machines are designed with optimized axle kinematics in order to minimize travel ranges, especially for small, 5-axis parts. Highly economical linear axes and generous tilt and rotational axes, combined with their optimized spatial arrangement, enable complicated free-form geometries to be machined with the lowest possible travel ranges, in a single clamping.

Patented machine stands

The symmetrical, gantry design of KERN machines with a machine stand made from KERN Amorith (mineral casting, reinforced with heavy steel struts) suppresses virtually all oscillations by virtue of its weight and patented material.

– Interfaces for all commercial automation

Automation

KERN CNC machining centers have standardized interfaces for all common automation systems. With the ability of a KERN to be integrated into any existing production system, our machines offer maximum flexibility and security for your automation tasks.

The automation of a KERN machine does not interrupt servicing work, since the main door to the machinery area remains constantly accessible.

KERN Evo manufacturing cell ER6
KERN Micro: Integrated workpiece changer
KERN Micro: Video integrated workpiece changer

Automation

KERN CNC machining centers have standardized interfaces for all common automation systems. With the ability of a KERN to be integrated into any existing production system, our machines offer maximum flexibility and security for your automation tasks.

The automation of a KERN machine does not interrupt servicing work, since the main door to the machinery area remains constantly accessible.

Your advantage:

  • Unmanned, stable serial production, 7 days per week
  • Increase of turn over through unmanned night shifts
  • Operating of multiple machine tools through only one user
  • Now, with the KERN Micro’s new integrated workpiece changer, you too can easily enter the world of automation.

Your benefits:

  • Deploy unmanned shifts (nights & weekends)
  • Pays for itself in under 12 months
  • No additional set-up space needed
  • No additional software or interfaces needed
  • Exploit the high process stability of the KERN Micro

– Intelligent thermal management for optimal temperature regulation of all machine components

Temperature stability

KERN Microtechnik has developed a sophisticated thermal management system for its machining centers which is perfectly matched to the requirements of each KERN machine.

Due to proprietary software algorithms the heat is dissipated in a controlled manner at the places where the temperature is produced. That’s the reason why KERN machines achieve an extremely high temperature stability – without influencing the indoor climate.

By drastically reducing the thermal sources of error, this intelligent control of the complete machine periphery, including the cooling lubricants, is one of the basis for our KERN potential.

Your benefits:

  • Constant zero and kinematic points for almost unlimited periods
  • Significant higher process stability results in significantly reduced quality assurance costs
  • Payback on your investment costs due to high energy efficiency

– Perfect ergonomics with full access to the working space as well as free access to the mounting area

Product design

When designing our machines, we take into account all aspects of automated serial production — from automatic tool change to ergonomics at each access point.

Tool change

For fast and safe tool changes during serial production runs, all KERN machines provide the ability to load the tool magazine during machining. A large number of tool slots allows long periods of autonomic operation; the tools are optimal and clearly arranged. The quick-change system of the KERN Micro is patented.

Ergonomics

The optimal accessibility and clamping height of every KERN machine ensures ergonomic working. The work space is bright, easily visible and accessible at all times by a main door – even with the machine running under automation.

Axle kinematics

KERN machines are designed with optimized axle kinematics in order to minimize travel ranges, especially for small, 5-axis parts. Highly economical linear axes and generous tilt and rotational axes, combined with their optimized spatial arrangement, enable complicated free-form geometries to be machined with the lowest possible travel ranges, in a single clamping.

Patented machine stands

The symmetrical, gantry design of KERN machines with a machine stand made from KERN Amorith (mineral casting, reinforced with heavy steel struts) suppresses virtually all oscillations by virtue of its weight and patented material.

– One-Box design

Product design

When designing our machines, we take into account all aspects of automated serial production — from automatic tool change to ergonomics at each access point.

Tool change

For fast and safe tool changes during serial production runs, all KERN machines provide the ability to load the tool magazine during machining. A large number of tool slots allows long periods of autonomic operation; the tools are optimal and clearly arranged. The quick-change system of the KERN Micro is patented.

Ergonomics

The optimal accessibility and clamping height of every KERN machine ensures ergonomic working. The work space is bright, easily visible and accessible at all times by a main door – even with the machine running under automation.

Axle kinematics

KERN machines are designed with optimized axle kinematics in order to minimize travel ranges, especially for small, 5-axis parts. Highly economical linear axes and generous tilt and rotational axes, combined with their optimized spatial arrangement, enable complicated free-form geometries to be machined with the lowest possible travel ranges, in a single clamping.

Patented machine stands

The symmetrical, gantry design of KERN machines with a machine stand made from KERN Amorith (mineral casting, reinforced with heavy steel struts) suppresses virtually all oscillations by virtue of its weight and patented material.

When productivity and precision really count

The KERN Micro is ideal for all industries requiring ultra-high precision in serial production.

– Tool/mold production

High precision and stable operation for both direct and electrode milling

Tool, mold and manufacture

In microtechnology, manufacturers of shaping and cutting dies and molds are often tasked with precise machining of very hard materials. All CNC Machining centers by KERN Microtechnik are perfectly suited to the direct milling of hardened steels or even carbide as well as milling with copper, tungsten copper and graphite electrodes.

Direct hard milling with KERN — your benefits

  • High-quality surface finish due to HSC spindles with maximal smoothness, hydrostatic pivots and perfect contour control via iTNC530 or TNC 640
  • Milling of free-form surfaces with high precision through μ-exact spindle movements and 5-axis simultaneous milling
  • Very high absolute accuracy thanks to perfect calibration between tool and workpiece in all KERN machines
  • Short set-up times for small production batches

Electrode milling with KERN — your benefits

  • Very high absolute accuracy as a basis for stable EDM processes
  • High-quality surface finish due to HSC spindles with maximal smoothness, hydrostatic pivots and perfect contour control via iTNC530 or TNC 640
  • Extremely high repeat accuracy: thanks to perfect thermal management every KERN machine enables absolutely stable unmanned serial production (using proprietary technologies)

– Automotive

Ideal for flexible production of part families through modular programming in coordination with the CIP

Automotive

The KERN Micro and KERN Evo CNC machining centers by KERN Microtechnik are a supreme match for the extraordinarily high expectations and requirements which the automotive industry places on serial production machines. KERN machines distinguish themselves by exceeding the highest quality standards and delivering extreme process stability and reliability — while being specifically optimized for unmanned, 24/7 production.

KERN machines are especially well suited to meeting the following requirements of the automotive industry:

  • Short set-up times due to modular programming for flexible production of entire families of parts
  • Integrated measuring technology for maximum part reliability
  • Professional service availability
  • Permanent process optimization in close coordination with the customer-specific Continuous Improvement Process (CIP)

– Dental equipment

Universal applications for manufacturing complex geometric shapes from a variety of very hard materials

Dental equipment

Dental technology products, for example, dental prostheses, require precision machines capable of rapidly milling highly varying workpieces made from very hard materials like titanium and ceramics. Dental prostheses are frequently made and fitted for the patient on the same day, placing especially high demands for reliability and flexibility on the CNC machining center being used.

KERN Microtechnik possesses long-standing experience of the dental industry’s unique requirements. With the KERN Micro, KERN Microtechnik has developed a universal machine capable of not only processing the widest range of very hard materials but also of fast and precise milling of complex geometric forms. Thanks to extensive automation and short processing times, KERN Micro offers the dental industry sustained precision during continuous operation.

Overview of the advantages for the dental industry:

  • Maximum vibration control enables optimal tool life
  • Fewer compensatory movements and reduced processing times due to optimized kinematics
  • 5-axis machining with optimal accessibility and pressure angles
  • Reduced maintenance thanks to intelligent chip flow
  • Comprehensive automation possibilities

– Medical equipment

For complex geometries using high grade materials like titanium, chromium, stainless steel, ceramics or specialized plastics

Medical equipment

Medical products, e.g. precision components in surgical instruments, are manufactured from premium, hard to process materials like titanium, chromium cobalt, stainless steel, ceramics or especially hard plastics (e.g. PEEK or polyacetal). Their ability to be easily and hygienically cleaned is particularly important, making the quality requirements correspondingly high for CNC machining centers used for the serial production of medical equipment.

With the Micro CNC machining center KERN Microtechnik has developed a machine that superbly meets all of the medical industry’s criteria for supreme surface finish quality and geometric precision.

Overview of the advantages for the medical industry:

  • Maximum vibration control enables optimal tool life
  • Fewer compensatory movements and reduced processing times due to optimized kinematics
  • 5-axis machining with optimal accessibility and pressure angles
  • Reduced maintenance thanks to intelligent chip flow

– Micromechanics and the watch industry

Fulfilling the highest demand for (free-form) geometries, precision, repeat accuracy after tool changes, and surface finish

Micromechanics and the watch industry

Micromechanics — the production of microscopically small components — requires high volumes of precision-milled parts. Our KERN Evo and KERN Micro machines are not only optimized for automated high-speed manufacturing of watch plates and watch parts but also for light guide connection elements, medical endoscope heads and turbine wheels in the submillimeter range.

In close collaboration with a wide range of watchmakers, the performance of KERN’s high precision machining centers has been perfected right from the start. For many years, KERN machining centers have met the exacting demands of these industries for (free-form) geometric complexity, precision and surface finish, setting new standards for machining capabilities in the microtechnology sector.

The advantages of KERN machines for the microtechnology sector:

Intelligent chip management can be engaged for thorough cleaning and recycling of valuable materials

μ-exact probing allows maximum repeat accuracy during tool changes in processes with more than one clamping

Maximum process reliability ensures uniform quality and guarantees minimal waste

  • Intelligent chip management can be engaged for thorough cleaning and recycling of valuable materials
  • μ-exact probing allows maximum repeat accuracy during tool changes in processes with more than one clamping
  • Maximum process reliability ensures uniform quality and guarantees minimal waste

– Research and development

Widely employable across a vast range of high-tech research fields

Research and development

Our machines are making valuable contributions to high-level research projects in internationally renowned scientific institutions throughout Europe, Asia, USA, Brazil, Cuba and South Africa. Whether with KERN machines at our customers’ sites or at KERN’s contract production plant in Eschenlohe — KERN Microtechnik is an active development partner for high precision parts across a vast range of technologies and research fields:

  • Research in satellite technology
  • Nuclear fusion research (e.g. UK and USA)
  • Neurosurgery
  • Processing of hard to machine materials (high-alloy steel, titanium, sandwich materials)
  • CERN particle accelerator (Switzerland)

All KERN machines offer the following advantages for research and development applications:

  • Maximum precision through absolute positional accuracy and perfect temperature control
  • Maximum reliability and adherence to all industry standards guaranteeing low maintenance and servicing requirements

Axes: travel

  • X-axis350 mm
  • Y-axis220 mm
  • Z-axis250 mm
  • B-axis-110° to +110° option -180° to +110°
  • C-axis360° endless

Axes: dynamics

  • Vmax X, Y, Z30 m/min
  • amax X, Y, Z0 m/s2
  • vmax B100 1/min
  • vmax C200 1/min
  • full load torque B648 Nm
  • constant torque B360 Nm
  • holding torque B-axis (clamped)300 Nm
  • full load torque C135 Nm
  • constant torque C75 Nm

Automatic tool changer HSK 25

  • 20 positions, 101 positions, 209 positions
  • tool changing time< 3 s
  • chip to chip time< 4.5s
  • max. tool diameter for automatic tool change70 mm (each 2nd tool rack position not in use)
  • max. tool length for automatic tool change including tool holder 155 mm

Automatic tool changer HSK 40

  • 18 positions , 102 positions, 210 positions
  • tool changing time< 3 s
  • chip to chip time< 4.5s
  • max. tool diameter for automatic tool change70 mm (each 2nd tool rack position not in use)
  • max. tool length for automatic tool change including tool holder 155 mm

Numeric control

  • Heidenhain TNC640

Spindle HSK 25

  • nmax30.000 1/min
  • option (S1)50.000 1/min
  • full load torquemax (S1)1,6 Nm
  • powermax6 kW

Spindle HSK 40

  • nmax42.000 1/min
  • full load torquemax (S1)5,9 Nm
  • powermax15 kW

Clamping System on 5th axis

  • Erowa ITS 148
  • System 3R Magnum

KERN Micro Pro

Description Technologies Industries Specifications

Solution for precise serial production

Since its launch on the market, the Kern Micro has stood out from the competition by combining  extreme precision with unrivaled flexibility and performance. Based on a mature machine platform,  the Kern Micro Pro is a solution focused on the industrial environment and precision serial production.

In many applications the focus is not on achieving a sub-2 μm precision on the workpiece, but rather on the machine’s series stability, integration capability and cost-effectiveness. The sleek Kern Micro Pro is designed to perfectly meet these requirements.

– Minimal footprint of less than 4 m2

– Uninterrupted monitoring and maintenance of lubricants during operation

– Attractive purchase conditions and maintenance costs

– High dynamics and productivity thanks to proven components and processes

– Unmanned multi-shift operation thanks to an integrated changer for up to 210 tools and up to 30 workpieces

– Certified interfaces for external units and automation systems

Even more compact, even more efficient

Due to the consistent focus on serial production,  a machine was created that combines productivity, efficiency and reliability like no other.  The system is based on proven, high-quality KERN technology and guarantees reliability and stability over a long machine life.

– Production with minimal positional variance due to a positional accuracy of ± 1 μm

Minimal position deviation

The position accuracy of KERN Machines according to VDI/DGQ 3441 is legendary. Each machine is laser-measured to guarantee precise positions down to the μ — from the first to the 10,000th workpiece during unmanned serial production.

Position deviation KERN Micro: Pa = ± 0.5 μm
Position deviation KERN Evo: Pa = ± 0.5 μm
Position deviation KERN Pyramid Nano: Pa = ± 0.3 μm

Your advantage:

  • Maximum machining precision on the workpiece
  • Extremely stable processes through reliable repeatability
  • Reduced quality assurance costs
  • Reduced scrap parts

– Largest possible pivoting range on a floor area less than 4 qm

Product design

When designing our machines, we take into account all aspects of automated serial production — from automatic tool change to ergonomics at each access point.
Tool change
For fast and safe tool changes during serial production runs, all KERN machines provide the ability to load the tool magazine during machining. A large number of tool slots allows long periods of autonomic operation; the tools are optimal and clearly arranged. The quick-change system of the KERN Micro is patented.
Ergonomics
The optimal accessibility and clamping height of every KERN machine ensures ergonomic working. The work space is bright, easily visible and accessible at all times by a main door – even with the machine running under automation.
Axle kinematics
KERN machines are designed with optimized axle kinematics in order to minimize travel ranges, especially for small, 5-axis parts. Highly economical linear axes and generous tilt and rotational axes, combined with their optimized spatial arrangement, enable complicated free-form geometries to be machined with the lowest possible travel ranges, in a single clamping.
Patented machine stands
The symmetrical, gantry design of KERN machines with a machine stand made from KERN Amorith (mineral casting, reinforced with heavy steel struts) suppresses virtually all oscillations by virtue of its weight and patented material.

– Tool cabinet with quick-change plates for over 210 tools

Prodict design

When designing our machines, we take into account all aspects of automated serial production — from automatic tool change to ergonomics at each access point.
Tool change
For fast and safe tool changes during serial production runs, all KERN machines provide the ability to load the tool magazine during machining. A large number of tool slots allows long periods of autonomic operation; the tools are optimal and clearly arranged. The quick-change system of the KERN Micro is patented.
Ergonomics
The optimal accessibility and clamping height of every KERN machine ensures ergonomic working. The work space is bright, easily visible and accessible at all times by a main door – even with the machine running under automation.
Axle kinematics
KERN machines are designed with optimized axle kinematics in order to minimize travel ranges, especially for small, 5-axis parts. Highly economical linear axes and generous tilt and rotational axes, combined with their optimized spatial arrangement, enable complicated free-form geometries to be machined with the lowest possible travel ranges, in a single clamping.
Patented machine stands
The symmetrical, gantry design of KERN machines with a machine stand made from KERN Amorith (mineral casting, reinforced with heavy steel struts) suppresses virtually all oscillations by virtue of its weight and patented material.

– Interfaces for all commercial automation

Automation

KERN CNC machining centers have standardized interfaces for all common automation systems. With the ability of a KERN to be integrated into any existing production system, our machines offer maximum flexibility and security for your automation tasks.

The automation of a KERN machine does not interrupt servicing work, since the main door to the machinery area remains constantly accessible.

KERN Evo manufacturing cell ER6
KERN Micro: Integrated workpiece changer
KERN Micro: Video integrated workpiece changer

Automation
KERN CNC machining centers have standardized interfaces for all common automation systems. With the ability of a KERN to be integrated into any existing production system, our machines offer maximum flexibility and security for your automation tasks.

The automation of a KERN machine does not interrupt servicing work, since the main door to the machinery area remains constantly accessible.

Your advantage:

  • Unmanned, stable serial production, 7 days per week
  • Increase of turn over through unmanned night shifts
  • Operating of multiple machine tools through only one user
  • Now, with the KERN Micro’s new  integrated workpiece changer, you too can easily enter the world of automation.

Your benefits:

  • Deploy unmanned shifts (nights & weekends)
  • Pays for itself in under 12 months
  • No additional set-up space needed
  • No additional software or interfaces needed
  • Exploit the high process stability of the KERN Micro

– Intelligent thermal management for optimal temperature regulation of all machine components

Temperature stability

KERN Microtechnik has developed a sophisticated thermal management system for its machining centers which is perfectly matched to the requirements of each KERN machine.

Due to proprietary software algorithms the heat is dissipated in a controlled manner at the places where the temperature is produced. That’s the reason why KERN machines achieve an extremely high temperature stability – without influencing the indoor climate.

By drastically reducing the thermal sources of error, this intelligent control of the complete machine periphery, including the cooling lubricants, is one of the basis for our KERN potential.

Your benefits:

  • Constant zero and kinematic points for almost unlimited periods
  • Significant higher process stability results in significantly reduced quality assurance costs
  • Payback on your investment costs due to high energy efficiency

– Perfect ergonomics with full access to the working space as well as free access to the mounting area

Product design

When designing our machines, we take into account all aspects of automated serial production — from automatic tool change to ergonomics at each access point.
Tool change
For fast and safe tool changes during serial production runs, all KERN machines provide the ability to load the tool magazine during machining. A large number of tool slots allows long periods of autonomic operation; the tools are optimal and clearly arranged. The quick-change system of the KERN Micro is patented.
Ergonomics
The optimal accessibility and clamping height of every KERN machine ensures ergonomic working. The work space is bright, easily visible and accessible at all times by a main door – even with the machine running under automation.
Axle kinematics
KERN machines are designed with optimized axle kinematics in order to minimize travel ranges, especially for small, 5-axis parts. Highly economical linear axes and generous tilt and rotational axes, combined with their optimized spatial arrangement, enable complicated free-form geometries to be machined with the lowest possible travel ranges, in a single clamping.
Patented machine stands
The symmetrical, gantry design of KERN machines with a machine stand made from KERN Amorith (mineral casting, reinforced with heavy steel struts) suppresses virtually all oscillations by virtue of its weight and patented material.

– One-box design

Product design

When designing our machines, we take into account all aspects of automated serial production — from automatic tool change to ergonomics at each access point.
Tool change
For fast and safe tool changes during serial production runs, all KERN machines provide the ability to load the tool magazine during machining. A large number of tool slots allows long periods of autonomic operation; the tools are optimal and clearly arranged. The quick-change system of the KERN Micro is patented.
Ergonomics
The optimal accessibility and clamping height of every KERN machine ensures ergonomic working. The work space is bright, easily visible and accessible at all times by a main door – even with the machine running under automation.
Axle kinematics
KERN machines are designed with optimized axle kinematics in order to minimize travel ranges, especially for small, 5-axis parts. Highly economical linear axes and generous tilt and rotational axes, combined with their optimized spatial arrangement, enable complicated free-form geometries to be machined with the lowest possible travel ranges, in a single clamping.
Patented machine stands
The symmetrical, gantry design of KERN machines with a machine stand made from KERN Amorith (mineral casting, reinforced with heavy steel struts) suppresses virtually all oscillations by virtue of its weight and patented material.

When productivity and precision really count

The KERN Micro is ideal for all industries requiring ultra-high precision in serial production.

– Tool/mold production

High precision and stable operation for both direct and electrode milling

Tool, mold and manufacture

In microtechnology, manufacturers of shaping and cutting dies and molds are often tasked with precise machining of very hard materials. All CNC Machining centers by KERN Microtechnik are perfectly suited to the direct milling of hardened steels or even carbide as well as milling with copper, tungsten copper and graphite electrodes.

Direct hard milling with KERN — your benefits

  • High quality surface finish due to HSC spindles with maximal smoothness, hydrostatic pivots and perfect contour control via iTNC530 or TNC 640
  • Milling of free-form surfaces with high precision through μ-exact spindle movements and 5-axis simultaneous milling
  • Very high absolute accuracy thanks to perfect calibration between tool and workpiece in all KERN machines
  • Short set-up times for small production batches

Electrode milling with KERN — your benefits

  • Very high absolute accuracy as a basis for stable EDM processes
  • High quality surface finish due to HSC spindles with maximal smoothness, hydrostatic pivots and perfect contour control via iTNC530 or TNC 640
  • Extremely high repeat accuracy: thanks to perfect thermal management every KERN machine enables absolutely stable unmanned serial production (using proprietary technologies)

– Automotive

Ideal for flexible production of part families through modular programming in coordination with the CIP

Automotive

The KERN Micro and KERN Evo CNC machining centers by KERN Microtechnik are a supreme match for the extraordinarily high expectations and requirements which the automotive industry places on serial production machines. KERN machines distinguish themselves by exceeding the highest quality standards and delivering extreme process stability and reliability — while being specifically optimized for unmanned, 24/7 production.

KERN machines are especially well suited to meeting the following requirements of the automotive industry:

  • Short set-up times due to modular programming for flexible production of entire families of parts
  • Integrated measuring technology for maximum part reliability
  • Professional service availability
  • Permanent process optimization in close coordination with the customer-specific Continuous Improvement Process (CIP)

– Dental equipment

Universal applications for manufacturing complex geometric shapes from a variety of very hard materials

Dental equipment

Dental technology products, for example dental prostheses, require precision machines capable of rapidly milling highly varying workpieces made from very hard materials like titanium and ceramics. Dental prostheses are frequently made and fitted for the patient on the same day, placing especially high demands for reliability and flexibility on the CNC machining center being used.

KERN Microtechnik possesses long-standing experience of the dental industry’s unique requirements. With the KERN Micro KERN Microtechnik has developed a universal machine capable of not only processing the widest range of very hard materials, but also of fast and precise milling of complex geometric forms. Thanks to extensive automation and short processing times, KERN Micro offers the dental industry sustained precision during continuous operation.

Overview of the advantages for the dental industry:

  • Maximum vibration control enables optimal tool life
  • Fewer compensatory movements and reduced processing times due to optimized kinematics
  • 5-axis machining with optimal accessibility and pressure angles
  • Reduced maintenance thanks to intelligent chip flow
  • Comprehensive automation possibilities

– Medical equipment

For complex geometries using high grade materials like titanium, chromium, stainless steel, ceramics or specialized plastics

Medical equipment

Medical products, e.g. precision components in surgical instruments, are manufactured from premium, hard to process materials like titanium, chromium cobalt, stainless steel, ceramics or especially hard plastics (e.g. PEEK or polyacetal). Their ability to be easily and hygienically cleaned is particularly important, making the quality requirements correspondingly high for CNC machining centers used for the serial production of medical equipment.

With the Micro CNC machining center KERN Microtechnik has developed a machine that superbly meets all of the medical industry’s criteria for supreme surface finish quality and geometric precision.

Overview of the advantages for the medical industry:

  • Maximum vibration control enables optimal tool life
  • Fewer compensatory movements and reduced processing times due to optimized kinematics
  • 5-axis machining with optimal accessibility and pressure angles
  • Reduced maintenance thanks to intelligent chip flow

– Micromechanics and the watch industry

Fulfilling the highest demand for (free-form) geometries, precision, repeat accuracy after tool changes, and surface finish

Micromechanics and the watch industry

Micromechanics — the production of microscopically small components — requires high volumes of precision-milled parts. Our KERN Evo and KERN Micro machines are not only optimized for automated high speed manufacturing of watch plates and watch parts, but also for lightguide connection elements, medical endoscope heads and turbine wheels in the submillimeter range.

In close collaboration with a wide range of watchmakers, the performance of KERN’s high precision machining centers has been perfected right from the start. For many years, KERN machining centers have met the exacting demands of these industries for (free-form) geometric complexity, precision and surface finish, setting new standards for machining capabilities in the microtechnology sector.

The advantages of KERN machines for the microtechnology sector:

Intelligent chip management can be engaged for thorough cleaning and recycling of valuable materials

μ-exact probing allows maximum repeat accuracy during tool changes in processes with more than one clamping

Maximum process reliability ensures uniform quality and guarantees minimal waste

  • Intelligent chip management can be engaged for thorough cleaning and recycling of valuable materials
  • μ-exact probing allows maximum repeat accuracy during tool changes in processes with more than one clamping
  • Maximum process reliability ensures uniform quality and guarantees minimal waste

– Research and development

Widely employable across a vast range of high-tech research fields

Research and development

Our machines are making valuable contributions to high level research projects in internationally renowned scientific institutions throughout Europe, Asia, USA, Brazil, Cuba and South Africa. Whether with KERN machines at our customers’ sites or at KERN’s contract production plant in Eschenlohe — KERN Microtechnik is an active development partner for high precision parts across a vast range of technologies and research fields:

  • Research in satellite technology
  • Nuclear fusion research (e.g. UK and USA)
  • Neurosurgery
  • Processing of hard to machine materials (high-alloy steel, titanium, sandwich materials)
  • CERN particle accelerator (Switzerland)

All KERN machines offer the following advantages for research and development applications:

  • Maximum precision through absolute positional accuracy and perfect temperature control
  • Maximum reliability and adherence to all industry standards guaranteeing low maintenance and servicing requirements

Axes: travel

  • X-axis350 mm
  • Y-axis220 mm
  • Z-axis250 mm
  • B-axis-110° to +110° option -180° to +110°
  • C-axis360° endless

Axes: dynamics

  • vmax X, Y, Z30 m/min
  • amax X, Y, Z0 m/s2
  • vmax B100 1/min
  • vmax C200 1/min
  • full load torque B648 Nm
  • constant torque B360 Nm
  • holding torque B-axis (clamped)300 Nm
  • full load torque C135 Nm
  • constant torque C75 Nm

Automatic tool changer HSK 25

  • 20 positions, 101 positions, 209 positions
  • tool changing time< 3 s
  • chip to chip time< 4.5s
  • max. tool diameter for automatic tool change70 mm (each 2nd tool rack position not in use)
  • max. tool length for automatic tool change including tool holder 150 mm

Automatic tool changer HSK 40

  • 18 positions , 90 positions, 186 positions
  • tool changing time< 3 s
  • chip to chip time< 4.5s
  • max. tool diameter for automatic tool change70 mm (each 2nd tool rack position not in use)
  • max. tool length for automatic tool change including tool holder 150 mm

Numeric control

  • Heidenhain TNC640

Spindle HSK 25

  • nmax30.000 1/min
  • nmax (optional)50.000 1/min
  • full load torquemax (S1)1,6 Nm
  • powermax (s1)6 kW

Spindle HSK 40

  • nmax42.000 1/min
  • full load torquemax (S1)5,9 Nm
  • powermax (S1)15 kW

Spindle HSK 32

  • nmax40.000 1/min
  • full load torquemax (S1)2,1 Nm
  • powermax (S1)6,3 kW

Clamping System on 5th axis

  • Erowa ITS 148
  • System 3R Magnum

KERN Specialty Machines

KERN Evo

Description Technologies Industries Specifications

The result of intelligent evolution!

Every KERN Evo contains many years of consistent development to ensure ultra-high precision in CNC milling at high and medium volumes.

With its proprietary X-Y cross table, KERN Evo delivers maximum precision in a small installation space. The design allows maximum smoothness and excellent surface finish (Ra < 1 μm) even at high speeds and acceleration values.

Short distances between components and drives ensure minimal angle errors, while ultra-high resolution direct measuring systems guarantee maximum repeat accuracy in a working space of 300 x 300mm. KERN Evo can be optionally equipped with a 4th and 5th axis without compromising the stability and high precision of the basic machine.

With high quality components in all peripheral modules and easy automation, KERN Evo is widely used for unmanned 3-shift production in all industries that demand maximum precision on the workpiece.

Advanced technologies for maximum precision

The incorporation of sophisticated, mature technologies makes KERN Evo perfect for highly stable serial production tasks:

– Production with minimal positional variance due to a positional accuracy of ± 0.5 μm

Minimal position deviation

The position accuracy of KERN Machines according to VDI/DGQ 3441 is legendary. Each machine is laser-measured to guarantee precise positions down to the μ — from the first to the 10,000th workpiece during unmanned serial production.

Position deviation KERN Micro: Pa = ± 0.5 μm
Position deviation KERN Evo: Pa = ± 0.5 μm
Position deviation KERN Pyramid Nano: Pa = ± 0.3 μm

Your advantage:

  • Maximum machining precision on the workpiece
  • Extremely stable processes through reliable repeatability
  • Reduced quality assurance costs
  • Reduced scrap parts

– Interfaces to all commercial automation

Automation

KERN CNC machining centers have standardized interfaces for all common automation systems. With the ability of a KERN to be integrated into any existing production system, our machines offer maximum flexibility and security for your automation tasks.

The automation of a KERN machine does not interrupt servicing work, since the main door to the machinery area remains constantly accessible.

KERN Evo manufacturing cell ER6
KERN Micro: Integrated workpiece changer
KERN Micro: Video integrated workpiece changer

Automation
KERN CNC machining centers have standardized interfaces for all common automation systems. With the ability of a KERN to be integrated into any existing production system, our machines offer maximum flexibility and security for your automation tasks.

The automation of a KERN machine does not interrupt servicing work, since the main door to the machinery area remains constantly accessible.

Your advantage:

  • Unmanned, stable serial production, 7 days per week
  • Increase of turn over through unmanned night shifts
  • Operating of multiple machine tools through only one user
  • Now, with the KERN Micro’s new  integrated workpiece changer, you too can easily enter the world of automation.

Your benefits:

  • Deploy unmanned shifts (nights & weekends)
  • Pays for itself in under 12 months
  • No additional set-up space needed
  • No additional software or interfaces needed
  • Exploit the high process stability of the KERN Micro

-Intelligent thermal management for optimal temperature control of the spindle and cooling lubricant

Temperature stability

KERN Microtechnik has developed a sophisticated thermal management system for its machining centers which is perfectly matched to the requirements of each KERN machine.

Due to proprietary software algorithms the heat is dissipated in a controlled manner at the places where the temperature is produced. That’s the reason why KERN machines achieve an extremely high temperature stability – without influencing the indoor climate.

By drastically reducing the thermal sources of error, this intelligent control of the complete machine periphery, including the cooling lubricants, is one of the basis for our KERN potential.

Your benefits:

  • Constant zero and kinematic points for almost unlimited periods
  • Significant higher process stability results in significantly reduced quality assurance costs
  • Payback on your investment costs due to high energy efficiency

– Perfect ergonomics with full access to the working space as well as free access to the mounting area

 

Product design

When designing our machines, we take into account all aspects of automated serial production — from automatic tool change to ergonomics at each access point.
Tool change
For fast and safe tool changes during serial production runs, all KERN machines provide the ability to load the tool magazine during machining. A large number of tool slots allows long periods of autonomic operation; the tools are optimal and clearly arranged. The quick-change system of the KERN Micro is patented.
Ergonomics
The optimal accessibility and clamping height of every KERN machine ensures ergonomic working. The work space is bright, easily visible and accessible at all times by a main door – even with the machine running under automation.
Axle kinematics
KERN machines are designed with optimized axle kinematics in order to minimize travel ranges, especially for small, 5-axis parts. Highly economical linear axes and generous tilt and rotational axes, combined with their optimized spatial arrangement, enable complicated free-form geometries to be machined with the lowest possible travel ranges, in a single clamping.
Patented machine stands
The symmetrical, gantry design of KERN machines with a machine stand made from KERN Amorith (mineral casting, reinforced with heavy steel struts) suppresses virtually all oscillations by virtue of its weight and patented material.

For industries with challenging production conditions

KERN Evo is used across various industries, wherever maximum, μ-exact precision on the workpiece is demanded.

– Tool/mold production

High precision and stable operation for both direct and electrode milling

Tool, mold and manufacture

In microtechnology, manufacturers of shaping and cutting dies and molds are often tasked with precise machining of very hard materials. All CNC Machining centers by KERN Microtechnik are perfectly suited to the direct milling of hardened steels or even carbide as well as milling with copper, tungsten copper and graphite electrodes.

Direct hard milling with KERN — your benefits

  • High quality surface finish due to HSC spindles with maximal smoothness, hydrostatic pivots and perfect contour control via iTNC530 or TNC 640
  • Milling of free-form surfaces with high precision through μ-exact spindle movements and 5-axis simultaneous milling
  • Very high absolute accuracy thanks to perfect calibration between tool and workpiece in all KERN machines
  • Short set-up times for small production batches

Electrode milling with KERN — your benefits

  • Very high absolute accuracy as a basis for stable EDM processes
  • High quality surface finish due to HSC spindles with maximal smoothness, hydrostatic pivots and perfect contour control via iTNC530 or TNC 640
  • Extremely high repeat accuracy: thanks to perfect thermal management every KERN machine enables absolutely stable unmanned serial production (using proprietary technologies)

– Automotive

Ideal for flexible production of part families through modular programming in coordination with the CIP

Automotive

The KERN Micro and KERN Evo CNC machining centers by KERN Microtechnik are a supreme match for the extraordinarily high expectations and requirements which the automotive industry places on serial production machines. KERN machines distinguish themselves by exceeding the highest quality standards and delivering extreme process stability and reliability — while being specifically optimized for unmanned, 24/7 production.

KERN machines are especially well suited to meeting the following requirements of the automotive industry:

  • Short set-up times due to modular programming for flexible production of entire families of parts
  • Integrated measuring technology for maximum part reliability
  • Professional service availability
  • Permanent process optimization in close coordination with the customer-specific Continuous Improvement Process (CIP)

– Dental equipment

Universal applications for manufacturing complex geometric shapes from a variety of very hard materials

Dental equipment

Dental technology products, for example dental prostheses, require precision machines capable of rapidly milling highly varying workpieces made from very hard materials like titanium and ceramics. Dental prostheses are frequently made and fitted for the patient on the same day, placing especially high demands for reliability and flexibility on the CNC machining center being used.

KERN Microtechnik possesses long-standing experience of the dental industry’s unique requirements. With the KERN Micro KERN Microtechnik has developed a universal machine capable of not only processing the widest range of very hard materials, but also of fast and precise milling of complex geometric forms. Thanks to extensive automation and short processing times, KERN Micro offers the dental industry sustained precision during continuous operation.

Overview of the advantages for the dental industry:

  • Maximum vibration control enables optimal tool life
  • Fewer compensatory movements and reduced processing times due to optimized kinematics
  • 5-axis machining with optimal accessibility and pressure angles
  • Reduced maintenance thanks to intelligent chip flow
  • Comprehensive automation possibilities

– Medical equipment

For complex geometries using high grade materials like titanium, chromium, stainless steel, ceramics or specialized plastics

Medical equipment

Medical products, e.g. precision components in surgical instruments, are manufactured from premium, hard to process materials like titanium, chromium cobalt, stainless steel, ceramics or especially hard plastics (e.g. PEEK or polyacetal). Their ability to be easily and hygienically cleaned is particularly important, making the quality requirements correspondingly high for CNC machining centers used for the serial production of medical equipment.

With the Micro CNC machining center KERN Microtechnik has developed a machine that superbly meets all of the medical industry’s criteria for supreme surface finish quality and geometric precision.

Overview of the advantages for the medical industry:

  • Maximum vibration control enables optimal tool life
  • Fewer compensatory movements and reduced processing times due to optimized kinematics
  • 5-axis machining with optimal accessibility and pressure angles
  • Reduced maintenance thanks to intelligent chip flow

– Micromechanics and the watch industry

Fulfilling the highest demand for (free-form) geometries, precision, repeat accuracy after tool changes, and surface finish

Micromechanics and the watch industry

Micromechanics — the production of microscopically small components — requires high volumes of precision-milled parts. Our KERN Evo and KERN Micro machines are not only optimized for automated high speed manufacturing of watch plates and watch parts, but also for lightguide connection elements, medical endoscope heads and turbine wheels in the submillimeter range.

In close collaboration with a wide range of watchmakers, the performance of KERN’s high precision machining centers has been perfected right from the start. For many years, KERN machining centers have met the exacting demands of these industries for (free-form) geometric complexity, precision and surface finish, setting new standards for machining capabilities in the microtechnology sector.

The advantages of KERN machines for the microtechnology sector:

Intelligent chip management can be engaged for thorough cleaning and recycling of valuable materials

μ-exact probing allows maximum repeat accuracy during tool changes in processes with more than one clamping

Maximum process reliability ensures uniform quality and guarantees minimal waste

  • Intelligent chip management can be engaged for thorough cleaning and recycling of valuable materials
  • μ-exact probing allows maximum repeat accuracy during tool changes in processes with more than one clamping
  • Maximum process reliability ensures uniform quality and guarantees minimal waste

– Research and development

Widely employable across a vast range of high-tech research fields

Research and development

Our machines are making valuable contributions to high level research projects in internationally renowned scientific institutions throughout Europe, Asia, USA, Brazil, Cuba and South Africa. Whether with KERN machines at our customers’ sites or at KERN’s contract production plant in Eschenlohe — KERN Microtechnik is an active development partner for high precision parts across a vast range of technologies and research fields:

  • Research in satellite technology
  • Nuclear fusion research (e.g. UK and USA)
  • Neurosurgery
  • Processing of hard to machine materials (high-alloy steel, titanium, sandwich materials)
  • CERN particle accelerator (Switzerland)

All KERN machines offer the following advantages for research and development applications:

  • Maximum precision through absolute positional accuracy and perfect temperature control
  • Maximum reliability and adherence to all industry standards guaranteeing low maintenance and servicing requirements

Axes: travel

  • X-axis300 mm
  • Y-axis280 mm
  • Z-axis250 mm
  • B-axis-10° to +100° (pivoting)
  • C-axis360° endless

Axes: dynamics

  • Vmax X, Y, Z16 m/min
  • amax X, Y, Z8 m/s2
  • vmax B8,5 1/min
  • vmax C20 1/min
  • full load torque B24 Nm
  • constant torque B12 Nm
  • full load torque C36 Nm
  • constant torque C18 Nm

Automatic tool changer HSK 25

  • 32 positions, 63 positions, 95 position
  • tool changing time < 3s
  • chip to chip time< 5s
  • max. tool diameter for automatic tool change50 mm (each 2nd tool rack position not used)
  • max. tool length for automatic tool change including tool holder110 mm

Numeric control

  • Heidenhain iTNC530

Spindle HSK 25

  • nmax50.000 1/min
  • full load torquemax (S1)1.43 Nm
  • full load torquemax (S6)1.86 Nm
  • powermax6 kW
  • crash control by DCM (optional)
  • permanent grease lubrication
  • positive air flow nozzle, cold air nozzle, MQL lubrication, flood cooling (optional)

Clamping system on 5th axis

  • Erowa ITS 50
  • System 3R Macro

KERN Pyramid Nano

Description Technologies Industries Specifications

Perfection in every dimension

The KERN Pyramid Nano is designed for applications that demand the highest precision and surface quality, even with large workpieces that require short machining times. With the integrated workpiece changer, the KERN Pyramid Nano can also be used in unmanned operation, even for 5-axis simultaneous machining assignments.

Driven by hydrostatic bearings and guidings, KERN Pyramid Nano is one of the most precise CNC machining centers in the world. By focusing on reliability in serial operation, this machine achieves ultra-precision manufacturing of industrial workloads.

Advanced technology for μ-accurate serial production

At the heart of the machine are the axes, which are mounted on hydrostatic bearings and therefore promise virtually wear-free precision throughout its lifetime. This means the quality and precision of all axes remain constant over extremely long time-frames. In addition, the hydrostatic system enables high acceleration with excellent vibration damping, bringing productivity and precision into perfect harmony. In combination with KERN’s proprietary temperature management system, an optimally
configured machine system is guaranteed at all times.

KERN’s sophisticated, mature product technologies give KERN Pyramid Nano significant advantages in precision manufacturing:

– Hydrostatics for smooth and wear-free manufacturing of precision parts

Hydrostatics

Due to their higher energy efficiency, hydrostatic guides and thread drives leave the competition standing. KERN Microtechnik is a pioneer in the use of this technology in precision engineering.

Our KERN Pyramid Nano machining center distinguishes itself by using axes driven by hydrostatic bearings that allow nano-precision, maximum surface quality, high acceleration and excellent vibration damping over virtually unlimited periods of time.

Your advantages:

  • Completely friction free
  • Nostick- slip effect
  • No wear and tear
  • High rigidity
  • Optimal temperature regulation, as all heat sources are outside the machine
  • Maximum vibration damping
  • Low energy costs

– Manufacturing with minimal dimensional variance due to a precision of ± 0.3 μm

Minimal position deviation

The position accuracy of KERN Machines according to VDI/DGQ 3441 is legendary. Each machine is laser-measured to guarantee precise positions down to the μ — from the first to the 10,000th workpiece during unmanned serial production.

Position deviation KERN Micro: Pa = ± 0.5 μm
Position deviation KERN Evo: Pa = ± 0.5 μm
Position deviation KERN Pyramid Nano: Pa = ± 0.3 μm

Your advantage:

  • Maximum machining precision on the workpiece
  • Extremely stable processes through reliable repeatability
  • Reduced quality assurance costs
  • Reduced scrap parts

– Intelligent thermal management system for optimal temperature control of all machine components

Temperature stability

KERN Microtechnik has developed a sophisticated thermal management system for its machining centers which is perfectly matched to the requirements of each KERN machine.

Due to proprietary software algorithms the heat is dissipated in a controlled manner at the places where the temperature is produced. That’s the reason why KERN machines achieve an extremely high temperature stability – without influencing the indoor climate.

By drastically reducing the thermal sources of error, this intelligent control of the complete machine periphery, including the cooling lubricants, is one of the basis for our KERN potential.

Your benefits:

  • Constant zero and kinematic points for almost unlimited periods
  • Significant higher process stability results in significantly reduced quality assurance costs
  • Payback on your investment costs due to high energy efficiency

– Interfaces to all commercial automation

Automation

KERN CNC machining centers have standardized interfaces for all common automation systems. With the ability of a KERN to be integrated into any existing production system, our machines offer maximum flexibility and security for your automation tasks.

The automation of a KERN machine does not interrupt servicing work, since the main door to the machinery area remains constantly accessible.

KERN Evo manufacturing cell ER6
KERN Micro: Integrated workpiece changer
KERN Micro: Video integrated workpiece changer

Automation
KERN CNC machining centers have standardized interfaces for all common automation systems. With the ability of a KERN to be integrated into any existing production system, our machines offer maximum flexibility and security for your automation tasks.

The automation of a KERN machine does not interrupt servicing work, since the main door to the machinery area remains constantly accessible.

Your advantage:

  • Unmanned, stable serial production, 7 days per week
  • Increase of turn over through unmanned night shifts
  • Operating of multiple machine tools through only one user
  • Now, with the KERN Micro’s new  integrated workpiece changer, you too can easily enter the world of automation.

Your benefits:

  • Deploy unmanned shifts (nights & weekends)
  • Pays for itself in under 12 months
  • No additional set-up space needed
  • No additional software or interfaces needed
  • Exploit the high process stability of the KERN Micro

– Perfect ergonomics with full access to the working space as well as free access to the mounting area

Product design

When designing our machines, we take into account all aspects of automated serial production — from automatic tool change to ergonomics at each access point.
Tool change
For fast and safe tool changes during serial production runs, all KERN machines provide the ability to load the tool magazine during machining. A large number of tool slots allows long periods of autonomic operation; the tools are optimal and clearly arranged. The quick-change system of the KERN Micro is patented.
Ergonomics
The optimal accessibility and clamping height of every KERN machine ensures ergonomic working. The work space is bright, easily visible and accessible at all times by a main door – even with the machine running under automation.
Axle kinematics
KERN machines are designed with optimized axle kinematics in order to minimize travel ranges, especially for small, 5-axis parts. Highly economical linear axes and generous tilt and rotational axes, combined with their optimized spatial arrangement, enable complicated free-form geometries to be machined with the lowest possible travel ranges, in a single clamping.
Patented machine stands
The symmetrical, gantry design of KERN machines with a machine stand made from KERN Amorith (mineral casting, reinforced with heavy steel struts) suppresses virtually all oscillations by virtue of its weight and patented material.

-Advanced jig grinding technology for processing the hardest materials

Jig grinding technology

Hydrostatic milling and grinding in a single clamping.

With its hydrostatic guides and drives, the KERN Pyramid Nano is ideal not only for milling but also for grinding.

With the optional KERN jig grinding package, your KERN Pyramid Nano can be configured with modular building blocks from the world of grinding technology:

Dressing units incl. dressing cycles
Ultrasonic sensors for zero-point location and contact monitoring
KO grinding cycles with freely programmable Z-axis motion
All modules are 100% integrated into the Heidenhain control system and can be freely used by NC programs and integrated into your processes.

Your benefits:

  • Increased precision through milling and grinding in a single clamping
  • Reduced lead times through milling and grinding in a single clamping
  • Maximum flexibility through freely programmable grinding contours
  • Grinding with maximum precision of Z-axis movement.

For industries requiring high precision

KERN Pyramid Nano is a perfect fit for all industries requiring maximum and ever-increasing precision. Which is why it is used for the most demanding applications both in industry and the research and development field.

– Tool/mold production

High precision and stable operation for both direct and electrode milling

Tool, mold and manufacture

In microtechnology, manufacturers of shaping and cutting dies and molds are often tasked with precise machining of very hard materials. All CNC Machining centers by KERN Microtechnik are perfectly suited to the direct milling of hardened steels or even carbide as well as milling with copper, tungsten copper and graphite electrodes.

Direct hard milling with KERN — your benefits

  • High quality surface finish due to HSC spindles with maximal smoothness, hydrostatic pivots and perfect contour control via iTNC530 or TNC 640
  • Milling of free-form surfaces with high precision through μ-exact spindle movements and 5-axis simultaneous milling
  • Very high absolute accuracy thanks to perfect calibration between tool and workpiece in all KERN machines
  • Short set-up times for small production batches

Electrode milling with KERN — your benefits

  • Very high absolute accuracy as a basis for stable EDM processes
  • High quality surface finish due to HSC spindles with maximal smoothness, hydrostatic pivots and perfect contour control via iTNC530 or TNC 640
  • Extremely high repeat accuracy: thanks to perfect thermal management every KERN machine enables absolutely stable unmanned serial production (using proprietary technologies)

– Medical equipment

For complex geometries using high grade materials like titanium, chromium, stainless steel, ceramics or specialized plastics

Medical equipment

Medical products, e.g. precision components in surgical instruments, are manufactured from premium, hard to process materials like titanium, chromium cobalt, stainless steel, ceramics or especially hard plastics (e.g. PEEK or polyacetal). Their ability to be easily and hygienically cleaned is particularly important, making the quality requirements correspondingly high for CNC machining centers used for the serial production of medical equipment.

With the Micro CNC machining center KERN Microtechnik has developed a machine that superbly meets all of the medical industry’s criteria for supreme surface finish quality and geometric precision.

Overview of the advantages for the medical industry:

  • Maximum vibration control enables optimal tool life
  • Fewer compensatory movements and reduced processing times due to optimized kinematics
  • 5-axis machining with optimal accessibility and pressure angles
  • Reduced maintenance thanks to intelligent chip flow

– High frequency technology

Stable serial production of key components with extremely high precision requirements

High frequency technology

The “digital revolution” has transformed mobile communications into a highly dynamic technology within a rapidly growing market. The key components in high frequency tech (and its complementary technologies) are subject to extremely stringent precision requirements. Despite this, they must also be producible in high volumes.

The KERN Pyramid Nano enables serial manufacture of such parts (e.g. wave guides) — even when they are already end products.

The advantages of KERN Pyramid Nano for high frequency technologies:

  • Hydrostatic guides and drives in all axes
  • Maximal reproducibility
  • Maximum smoothness and surface finish
  • High Z-stability across different speed ranges

– Research and development

Widely employable across a vast range of high-tech research fields

Research and development

Our machines are making valuable contributions to high level research projects in internationally renowned scientific institutions throughout Europe, Asia, USA, Brazil, Cuba and South Africa. Whether with KERN machines at our customers’ sites or at KERN’s contract production plant in Eschenlohe — KERN Microtechnik is an active development partner for high precision parts across a vast range of technologies and research fields:

  • Research in satellite technology
  • Nuclear fusion research (e.g. UK and USA)
  • Neurosurgery
  • Processing of hard to machine materials (high-alloy steel, titanium, sandwich materials)
  • CERN particle accelerator (Switzerland)

All KERN machines offer the following advantages for research and development applications:

  • Maximum precision through absolute positional accuracy and perfect temperature control
  • Maximum reliability and adherence to all industry standards guaranteeing low maintenance and servicing requirements

Axes: travel

  • X-axis500 mm
  • Y-axis500 mm
  • Z-axis400 mm
  • B-axis-20° to +110° (pivoting)
  • C-axis360° endless

Axes: dynamics

  • Vmax X, Y, Z30 m/min
  • amax X, Y, Z10 m/s2
  • vmax A800 1/min
  • vmaxC800 1/min
  • full load torque A77 Nm
  • constant torque A50 Nm
  • holding torque A-axis(clamped hydraulically)200 Nm
  • full load torque C39 Nm
  • constant torque C24 Nm

Automatic tool changer HSK 25

  • 32 positions, 64 positions, 96 positions
  • tool changing time< 3 s
  • chip to chip time< 5 s
  • max. tool diameter for automatic tool change60 mm (each 2nd tool rack position not used)
  • max. tool length for automatic tool change including tool holder160 mm

Automatic tool changer HSK 40

  • 25 positions, 50 positions, 75 positions
  • tool changing time< 3s
  • chip to chip time< 5 s
  • max. tool diameter for automatic tool change60 mm (each 2nd tool rack position not used)
  • max. tool length for automatic tool change including tool holder160 mm

Numeric control

  • Heidenhain iTNC530 / TNC640

Spindle HSK 25

  • nmax50.000 1/min
  • full load torquemax (S1)1.6 Nm
  • powermax7.8 kW

Spindle HSK 40

  • nmax42.000 1/min
  • full load torquemax (S1)5.9 Nm
  • full load torquemax (S6)8.0 Nm
  • powermax20 kW

Clamping system on 5th axis

  • Erowa ITS 148
  • System 3R Magnum
  • Hirschmann

KERN μ-View

Manufacturing with the perfect tool
Every tool failure costs time and money and delays your delivery schedule. That’s why KERN Microtechnik has developed a simple and very effective inspector for tool examination. Our KERN μ-View optical camera system provides images of tools with up to 450-fold magnification so you can easily spot defects.

Save money
μ-View’s pre-screening check detects defective tools before they are used in production. Thanks to accurate analysis it is also possible to monitor tools as they near their wear limits.