Gantry Milling Flexibility means being able to deliver on the same day if necessary

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The ability to accept orders flexibly is what makes Millcraft 3D competitive. To achieve this, the model and mould maker relies on F. Zimmermann. The latest addition to its machine park is an FZU32 gantry milling machine, whose precision goes far beyond the market standard.

“For many of our orders, the desired delivery date is ideally yesterday — and that’s not only the case with our motorsport customers,” says Sven Goldschmidt, Managing Director of Millcraft 3D, based in Backnang near Stuttgart.

Goldschmidt founded the company in 2016 together with his partners Sascha Guilliard and Sören Kura — at that time still located a few kilometres away in Affalterbach. All three brought strong contacts from their previous careers in the automotive industry.

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In addition to Formula 1 teams, Millcraft 3D counts major automotive manufacturers among its customers. The names remain confidential due to contractual obligations. Further customers come from traditional carbon processing, mechanical engineering and many other industries, including aerospace. The team machines components such as rotor blades and parts for drones. Due to the current geopolitical situation, demand from the defence sector has also increased. In addition, the machines are used to produce display models and exhibition pieces — including, for example, the vault door from the TV series Money Heist (Haus des Geldes) for the Gamescom trade fair.

For laminating the carbon components, Millcraft 3D sends the moulds to partner companies, which then return the finished parts for final machining. “We also produce one-off parts as well as components in larger quantities for our customers,” Goldschmidt adds. The portfolio also includes inspection, measuring and assembly fixtures, as well as design services and CAD/CAM programming. “By specialising in fibre-reinforced composites, we have successfully established a niche,” he explains. The company also machines foam materials, all common model-making materials, various plastics, aramid, aluminium and brass.

The most important resource, however, is the highly motivated team. “Without our employees, none of this would be possible,” Goldschmidt emphasises. “They bring deep expertise and a high level of personal responsibility, and everyone supports one another. Even the best machine park is useless without qualified staff.” That said, the machine park itself is also impressive.

The first step to success

Before Millcraft 3D could start processing its first orders in 2017, a suitable gantry milling machine was required. “One of my co-founders recommended machines from F. Zimmermann in nearby Neuhausen auf den Fildern, based on his own positive experience,” Goldschmidt recalls. “We chose the FZ33 Compact — it was the best decision of my entrepreneurial life.”

As a young company, the founders naturally had concerns about making such a major investment. “You can’t go wrong with our machine,” reassured Rudolf Gänzle, then Managing Director and senior shareholder at Zimmermann. “I’m certain you’ll buy a second machine from us.” He was right.

The FZ33 Compact enables fast five-sided complete machining of aluminium and composite components and supports highly dynamic simultaneous machining. This marked the beginning of rapid growth at Millcraft 3D: order volumes increased and the team expanded. In 2019 and 2020, two smaller, identical milling machines from another supplier were added, mainly for machining small and batch aluminium parts.

Growth with relocation

To continue processing customer orders flexibly and on time, another investment became necessary. “We had been keeping an eye on Zimmermann’s FZU32 for quite some time,” says Goldschmidt. The compact 5-axis gantry milling machine is particularly suited for machining aluminium, fibre-reinforced composites, plastics and Ureol. “We received government funding for this investment, which made the decision easier,” he adds.

However, space was an issue: the previous site in Affalterbach offered only 600 square metres, which were already fully utilised. The building, dating from 1979, was also not particularly representative — especially when Formula 1 teams or automotive manufacturers came to visit. Since the end of 2023, the company has been operating from a new building in neighbouring Backnang, offering more than 1,300 square metres. The production hall is state-of-the-art, energy-efficient and fully air-conditioned. Following the move, the team has grown to 13 employees plus one apprentice.

Machine structure absorbs thermal influences

Even in its standard configuration, the FZU32 exceeds the usual performance level. Its core concept is a thermosymmetrical design with a robust box-in-box structure. “The idea is that thermal influences can largely be absorbed by the machine structure,” explains Rüdiger Hellwig, Sales Director at F. Zimmermann. “Fluctuating ambient temperatures and process heat inevitably affect machine geometry in conventional gantry designs. That’s why we have carefully designed and intelligently arranged structural and drive components, guideways and other accuracy-relevant elements.”

The structure expands from the centre outward, ensuring that the milling tool remains precisely positioned at the centre. This results in high accuracy and long-term stability. Thanks to this precision, much of the rework normally required is eliminated, saving both time and capacity. “This allows our customers to respond faster, more cost-effectively and more flexibly to enquiries, significantly reducing lead times,” says Hellwig. As a result, Millcraft 3D remains flexible even for highly demanding orders.

The machine is equipped with a slim VH10 milling head with an HSK-A63 tool interface. Goldschmidt is particularly impressed by the machine’s energy efficiency, modern control panel and large working area of X = 3,000 mm, Y = 4,000 mm and Z = 1,500 mm.

The system also includes two chip conveyors and a coolant unit for wet machining. Currently clamped is a housing made from PA6. “This material is completely new to us,” Goldschmidt explains. “It contains 25 per cent glass fibres and 15 per cent carbon fibres, along with titanium, aluminium and foams.” The challenge: the component must not vibrate during machining and must not melt — making it an extremely demanding task. Initial tests for feed rates and tooling are now being carried out on the machine. The base body was additively manufactured by Millcraft 3D using its XXL 3D printer.

Flexibility required

“No two days are the same here,” Goldschmidt concludes. “We may start work at 7 a.m., and two hours later the entire day can look completely different.” That’s why flexibility is essential. Millcraft 3D has built a strong reputation among its customers, who know that if they call today, delivery may even be possible the next day. With the Zimmermann FZU32, this capability has improved further.

We have even managed to deliver on the very same day — for example, for Formula 1. When we then see our parts on television during a race, it’s a really great feeling, says Goldschmidt.

At Millcraft 3D, the machines are not just machines — they are part of the team. That’s why the employees have given them personal names: the forklift is called Gabi, while the two Zimmermann machines are named Emilly and Millissa — derived from the company name.

* Sandra Bayer Teixeira; Marketing; F. Zimmermann

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