Facility Layout & Equipment

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The Alpha Facility occupies approximately 8,000 square feet organized into seven functional zones designed for efficient material flow, operator visibility, and clean separation between precision and dirty operations. A 3-ton overhead bridge crane spans the machine bay for billet handling, vise swaps, and machine maintenance.

Zone Map

Zone	Function	Key Equipment
A: Machine Bay	CNC machining, per-machine workbenches	DVF 5000s, Lista benches, vise racks
B-Clean: Toolroom	Tool assembly, presetting, shrink fit	Haimer i4.0, VIO Linear, Tool Dynamic, HSK cabinet
B-Dirty: Toolroom	Grinding, sanding, deburring, tumbling	Bench grinder, belt sander, Rosler tumbler, blast cabinet
C: Metrology Lab	Final inspection, gauge storage, QC	Standridge 4x8 plate, TESA-Hite 700, QM-Height 600, Surftest SJ-210
D: Workholding	Vise storage, jaw inventory	Lang zero-point system, swappable vises
E: SLS Area	Soft jaw printing, depowdering	2x Formlabs Fuse 1+ 30W, Sift, Blast
F: Stock/Shipping	Billet storage, cutting, packing	Billet racks, Jet bandsaw, packing bench, chip management

Machine Arrangement

DVF 5000s are arranged in a 2-row facing configuration with a 5-foot center aisle. Each machine has a dedicated workbench with PACKOUT side-mount positioned immediately in front. Machine spacing is 4 feet minimum between units for door swing and maintenance access. The overhead crane (3-ton, 50-foot span) covers the entire machine bay.

Material Flow

Material enters through the roll-up door on the west wall into the stock/shipping zone. Billets are cut on the bandsaw if required, staged on racks, and flow east into the machine bay. After machining, parts move to the dirty toolroom for deburr/finishing, then to the metrology lab for inspection. Inspected parts return to shipping. SLS soft jaws flow from the SLS area into the machine bay. Tools flow from the clean toolroom to machines.

Clean Toolroom

• Haimer Power Clamp Premium i4.0: top-of-line shrink fit machine, NG coil auto-detect, 5 cooling bodies
• Haimer Power Cooler for rapid cooling
• Haimer Microset VIO Linear presetter: +/-2 micron repeatability, RFID, Sinumerik post-processor
• Haimer Tool Dynamic Micro balancer for HSK-A63 assemblies
• Lista HSK-A63 cabinet (120 positions), bench-top racks, wall-mount clips, endmill tube storage
• CDI torque wrenches, Wiha TorqueVario, complete Wera/Knipex hand tool set
• Stainless cleanroom workbench, HSK taper maintenance supplies

Dirty Toolroom

• Jet JBG-8A bench grinder (8 inch, variable speed)
• Jet JSG-96 belt/disc sander (6x48 inch belt + 9 inch disc)
• Rosler R 180 vibratory tumble finisher (1.8 cu ft, ceramic media)
• Blast cabinet (bench-top 25 inch siphon)
• Jet dust collector (1HP, wall-mount), heavy-duty deburr bench
• Jet HVBS-712D horizontal bandsaw (located in stock zone)

Machine-Side Equipment

Each DVF 5000 has an identical workbench station. Standardizing bench equipment ensures any operator can work at any station and the cell is fully replicable.

Workbench

• Lista 72x30 inch heavy-duty workbench with 7-drawer cabinet and foam inserts
• Wilton 746 bench vise, pegboard panel, overhead LED light bar, anti-fatigue mat
• Milwaukee PACKOUT mounting plate + compact and low-profile organizers

Hand Tools (per bench)

• Wera: Kraftform Kompakt 60, Zyklop Speed ratchet sets (1/4 + 3/8 + 1/2), Hex-Plus L-keys, Joker combo wrenches, T-handle hex, Chiseldriver set
• Knipex: Cobra 3pc set, Pliers Wrench, diagonal cutters, needle nose, TwinGrip, snap ring sets
• Milwaukee: dead blow set, ball peen, brass drifts, center punch, Fastback knife, tape measure, pry bars
• Noga/Shaviv deburring: NogaGrip + blades, Mini-Scraper, swivel-blade, Mango II set, needle files

M12 Cordless Platform (per bench)

• M12 FUEL stubby impact (3/8), right-angle die grinder (1/4), compact vacuum, 2x ratchets
• Shockwave socket sets (3/8 and 1/4, SAE + metric), 2x 4.0Ah batteries + charger

Measuring Equipment (per bench)

• Mitutoyo 6 + 12 inch digital calipers (Absolute IP67)
• Mitutoyo 0-1, 1-2, 2-3, 3-4 inch digital micrometers (IP65)
• Depth micrometer 0-6 inch, dial test indicator + mag base, combination square, Haimer 3D Taster

Metrology Lab

The metrology lab provides final inspection beyond on-machine probing.

Primary Equipment

• Standridge 48x96x8 inch Grade A granite surface plate on rolling stand
• TESA-Hite 700 electronic height gauge (0-28 inch, +/-2.5 micron)
• Mitutoyo QM-Height 600 digital height gauge (0-24 inch)
• Mitutoyo Surftest SJ-210 portable roughness tester
• CMM planned for Year 2 (benchtop CNC)

Gauge Inventory

• Thread plug + ring gauge sets: UNC, UNF, metric (GO/NO-GO)
• Pin gauge sets: 0.011-0.500 inch, metric 1.00-10.00mm, Class ZZ
• Mitutoyo 81-piece gauge block set, Grade 1 steel
• Digimatic bore gauges: 0.275-2.000 inch, all digital with setting rings
• Full 0-6 inch digital micrometer set with SPC output

Lab Environment

• Vibration-isolated workbench with granite insert, Waldmann LED task lamps
• Fluke 971 thermometer/hygrometer, HEPA air filtration, anti-static mats

Inspection System

On-Machine Probing

• Renishaw OMP40-2/OMP60 spindle probe (ATC Slot 101)
• Renishaw TS27R table-mounted tool setter (Slot 102)
• Probing in every cycle: datum, in-process, and final dimension checks
• Inspection data logged to QMS and customer portal automatically

Metrology Lab Verification

Parts flagged by on-machine probing, first-article parts, and customer-specified inspection requirements route to the metrology lab for surface plate verification using height gauges, bore gauges, thread gauges, and the Surftest SJ-210.