GK Series
4-Axis CNC Gantry Router with Swiveling Milling Head
Machine large 3D parts, freeform surfaces and sides in one setup – with a simultaneously controlled swiveling milling head.
Machine large parts without constant reclamping
Do you manufacture large parts, models or molds from foam and repeatedly reach the same limits during machining? Sides and steep flanks are difficult to reach, long cutters become unstable, or the workpiece has to be reclamped and realigned for further machining.
The GK Series is designed specifically for these tasks. Large foam and model-making blocks remain on the machine throughout the process, while top surfaces, freeform surfaces, flanks and sides can be machined from different tool angles.
The 180° swiveling milling head forms the 4th CNC axis and can be controlled simultaneously during machining. This allows the tool angle to follow the geometry of the part. Steep areas become easier to reach, shorter and more rigid cutters can often be used, and many operations can be completed in a single setup.
Typical applications include large parts made from EPS foam and PU foam, patterns, molds, foam furniture, formwork and model-making bodies. PU-coated foam parts can also be finish-machined flat and accurately to size.
With a standard working area of 6,000 × 3,000 mm and a working height of 1,000 mm, the GK Series is designed for large and bulky workpieces. Other dimensions can be manufactured to suit your part and block sizes.
The GK Series is therefore particularly suitable for users who want to machine large 3D geometries efficiently and reach as many surfaces of a part as possible without reclamping.
What can I produce?
The GK Series is designed for applications where large, bulky parts need to be machined from more than just the top. The simultaneously controlled swiveling milling head allows freeform surfaces, steep flanks and sides to be machined from different tool angles. This means many operations can be completed on the same workpiece in a single setup.
EPS structures & coated parts
EPS foam is used to produce large structures and components – for example foam building elements and large bodies. After PU coating, they can be finish-machined flat and accurately to size on the machine. With large parts in particular, it is useful to machine top and side areas without having to realign the part for every operation.
Foam furniture
Machine furniture, seating elements and organic components from foam in 3D – including sides, radii and smooth transitions. The swiveling milling head follows the geometry, allowing flowing transitions even on steep or side areas.
Patterns, molds & large models
Machine patterns, negative molds and large 3D models from foam and model-making blocks. This is where simultaneous 4-axis machining shows its strength: freeform surfaces, steep flanks and side areas can be machined with a favorable tool angle without reclamping the model.
Formwork & formwork construction
Foam blocks are used to produce formwork and formwork elements for concrete construction – for example for architectural concrete, facades, cornices and custom components. Complex freeform surfaces, angled faces and side contours can be machined directly from the block without repositioning the workpiece for each machining direction.
Which materials can I machine?
The GK Series is a CNC gantry router for blocks made from EPS foam and PU/PUR foam, for foam blocks such as upholstery and soft foam, and for special model-making/tooling blocks such as Ureol.
EPP sheets can also be machined. Metals such as aluminum, steel and stainless steel are not part of the intended application range.
EPS foam
The main EPS material is expanded polystyrene (EPS) in block form.
Typical parts include large EPS structures, building elements, models and large components – often used as a core for subsequent coating.
PU-coated EPS parts can also be finish-machined flat and accurately to size on the machine.
PU / PUR foam
PU materials include rigid polyurethane foams (PU/PUR) in block form.
Rigid PU foam is a key material for the GK Series. It is used to produce patterns, molds and dimensionally accurate 3D models with fine contours.
Foam
The machine processes upholstery foam, soft foam and similar foam materials.
Typical products include foam furniture, upholstery components, custom parts, packaging and shaped inserts.
Model-making and tooling blocks
In addition to foam blocks, the GK Series machines model-making and tooling blocks such as Ureol and comparable materials (e.g. RenShape/Necuron).
These denser blocks are suitable for precise patterns, molds and gauges with fine, dimensionally accurate contours.
How can I machine my parts?
Depending on the part, the GK Series can perform conventional 2.5D and 3D machining or control the 4th axis simultaneously. The key question is not the number of axes, but which surfaces of the workpiece you can reach in the same setup.
Machine contours, pockets and 3D surfaces
With 2.5D machining, contours, pockets, flat areas and operations are produced at defined Z levels. With 3D machining, the X, Y and Z axes move simultaneously. This allows freeform surfaces, spatial contours and three-dimensional shapes to be machined from the block.
Typical results include patterns, molds, furniture bodies and large 3D components.
For 3D machining, 3D CAM software calculates the toolpaths for the spatial geometry. 2.5D operations can also be programmed using the same machine kinematics.
Machine freeform surfaces and sides with simultaneous 4-axis motion
The key feature of the GK Series is the 180° swiveling milling head. It forms the 4th CNC axis and can be continuously controlled together with the three linear axes during machining.
During simultaneous 4-axis machining, the tool angle is continuously adapted to the geometry. This makes it possible to machine freeform surfaces with a more favorable tool orientation, reach steep flanks more effectively and often use shorter, more rigid cutters.
It also enables machining of sides, flanks and undercuts that would not be accessible from the same setup with pure 3-axis machining.
Top, freeform and side machining can be combined in one setup – without reclamping and without a second machine. Depending on the geometry, all four axes can work simultaneously. Eliminating reclamping saves time and helps maintain accuracy because the block remains in the same setup.
Table and workholding
The GK Series provides a stable, flat table surface; the customer builds the actual workholding solution on top of it to suit the workpieces.
Steel profile table with aluminum T-slot profiles
The machine table is made from rigid steel profiles. Aluminum T-slot profiles are bolted to the top.
The profiles provide a stable, continuous support surface with slots for attaching fixtures, stops and clamping devices.
Customer-specific workholding
The customer builds the workholding system on the T-slot profiles – for example stops, a fixture or a support structure on which the block is secured.
Depending on the application, large and heavy blocks can be bolted, clamped, located against stops or bonded in place.
Machine size and custom dimensions
The GK Series is built in the standard 6 × 3 m size, with a working area of 6,000 × 3,000 mm and a working height (Z) of 1,000 mm for large blocks.
If you need a larger working area or custom dimensions, we can manufacture your GK in other sizes. Contact us with your block dimensions.
|
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| Model | GK6030 |
|---|---|
| Working area L × W | 6.000 × 3.000 mm |
| Working height (Z) | 1.000 mm |
How quickly can I produce my part?
Machining time depends primarily on material, tool, cutting depth, surface requirements and geometry. A large foam block with long, consistent toolpaths is machined differently from a model with many tight radii, steep flanks and fine finishing contours.
As a guide, the machining feed rate on the large-format GK Series is often around 2–4 m/min. In practice, rapid and positioning moves are typically run at around 20 m/min; technically, speeds of up to 40 m/min are possible.
Routing and milling
During machining, the achievable feed rate is determined primarily by material, cutter, cutting depth and tool length. Soft foams can be removed quickly, while denser tooling blocks and fine finishing contours are machined at adapted feed rates.
Because of the large moving mass of the gantry, a moderate machining feed matched to the machine, tool and workpiece is used while cutting.
For foam and the selected cutter, suitable starting values for spindle speed, feed rate and depth of cut are used and then fine-tuned on the actual block.
Which cutters are used?
We supply the appropriate cutters to suit your application.
Cutters for the application
Depending on the material and task, we supply suitable cutters: long rasp cutters for EPS foam, special cutters for foam and custom cutters for specific requirements.
Foam can also be machined effectively with hollow cutters and integrated extraction – a high-quality, more expensive solution that we can discuss with you as an option.
How easy is the machine to operate?
Operating the machine itself is straightforward. The greater effort is usually in creating the drawings and programming the four axes in CAM.
From the drawing to the finished job
The process starts with the CAD drawing for the job. The machine program is then created from this geometry in the CAM software. Cutters, machining depths, head angles and the individual machining steps are defined there.
The completed machine program is loaded on the GK Series control PC, the block is clamped and machining is started. Tool changes and swiveling movements are carried out automatically within the prepared job.
Based on our experience, customers can work independently with the GK Series after one day of machine training, provided the CAD drawings are available or they know how to create them.
How do I get from a 3D file to the finished part?
The workflow remains clear for the operator: design the part → define machining in CAM → run the machine program on the GK Series. Technically, CAD, CAM and the machine software work together.
For 3D freeform, side and simultaneous 4-axis machining on the GK Series, 3D CAM software with suitable 4-axis support is used.
Step 1: Create the geometry
The geometry is created in a CAD program. For the three-dimensional workpieces machined on the GK Series, 3D CAD software such as SolidWorks or Autodesk Fusion is used.
Three-dimensional models are typically exported as STP files; STL files are mainly used for freeform surfaces and triangulated 3D models.
Step 2: Create the machine program
The machine program is created using 3D CAM software with 4-axis support, such as SolidCAM or Autodesk Fusion. The CAD geometry is loaded into the CAM software.
Tools, machining strategies, depths of cut and – for freeform surfaces, side machining and simultaneous 4-axis toolpaths – the movement of the swiveling milling head are defined there.
A suitable postprocessor converts the calculated toolpaths into the machine program for the GK Series. The postprocessor is provided and configured by the CAM software supplier, not by cnc-multitool.
Step 3: Machine the part
The program generated in CAM is loaded into the machine software on the control PC of the GK Series.
The machining job is then started from there. Tool changes and swiveling movements are executed according to the prepared machine program.
What happens if service is required?
If you need assistance, you can reach our technical team directly by phone or email. Many questions about machine software, control and machine operation can be resolved directly.
For software issues, our technician can connect to the GK Series control PC via TeamViewer and check settings and program sequences directly.
For technical faults, we work through troubleshooting with you – covering the control, sensors, electrical system and mechanics.
Spare and wear parts can be ordered directly from us and shipped at short notice.
If a fault cannot be resolved remotely, an on-site service technician can be deployed.
Machine features
With a machine of this size, what matters is not only what is installed technically, but what it delivers at the workpiece: repeatable positioning over long travel distances, stable tool guidance, reliable continuous operation and as little manual intervention as possible during a job.
Rigid steel frame
The gantry and machine frame are built from a rigid welded steel structure. After welding, the structure is heat-treated to reduce internal stresses.
The mounting surfaces for guides and drives are machined. This creates a torsion-resistant base that enables precise movement even in large-format machining. For you, this means that large workpieces can be machined repeatably over long travel distances.
Servo drives
Each CNC axis is driven by a servo motor. High-quality Yaskawa servo drives are used for axis control. They enable fast travel movements and precise axis positioning.
Position and movement are continuously controlled within the servo system. This enables both precise positioning and repeatable movement across the large working area. This is particularly important when a part extends over several meters and different surfaces are machined one after another.
Linear guides with central lubrication
All axes of the GK Series run on linear guides designed for large-format machines, mounted on the machined support surfaces of the steel frame.
This keeps the gantry backlash-free and repeatable even over the 6 m travel distance.
The linear guides are continuously supplied with lubricant by the automatic central lubrication system. This keeps routine maintenance low while ensuring the guides are lubricated regularly during operation.
Axis drives
The X and Y axes are driven by helical rack-and-pinion systems. This drive system enables long travel distances, high travel speeds and precise positioning – ideal for large-format machining.
The Z axis is driven by a ball screw, providing precise vertical positioning across the 1,300 mm travel.
Combined with the servo drives, this enables precise movement on all axes. For large components, this means long travel distances and accurate height positioning can be combined within the same job.
Machine sides and freeform surfaces without reclamping
The core feature of the GK Series is the 180° swiveling milling head. This 4th CNC axis moves the spindle from the vertical position to the required angle or can be controlled simultaneously during machining.
This allows freeform surfaces to be machined with an adapted tool orientation and also enables machining of sides, flanks and undercuts on large blocks – in one setup, without reclamping.
The swiveling motion is controlled by the machine program and can be either positioned or executed simultaneously with X, Y and Z. The practical advantage is that the tool orientation follows the part geometry instead of requiring the workpiece to be realigned for a different machining direction.
Electrical cabinet, control and computer
The central electrical cabinet houses the machine control, Yaskawa servo drives and power electronics of the GK Series.
The machine software runs on the control PC. It reads the prepared program and sends motion, spindle and swiveling commands to the machine control.
The machine control operates the axes, milling spindle, swiveling axis, tool changer and other machine functions.
9 kW milling spindle
The GK Series is equipped with an air-cooled 9 kW milling spindle with a maximum speed of 24,000 rpm.
Tools are held in ISO30 tool holders with ER32 collets. The spindle has pneumatic tool clamping for automatic tool changes.
Spindle speed is controlled by the machine software and can be adapted for each machining step to the foam, cutter and depth of cut.
Automatic tool changer
The GK Series has an automatic tool changer. Different cutters can therefore be changed automatically within a machine program.
The spindle automatically picks up the required cutter from the tool magazine and returns it afterwards, so an active block machining job does not have to be stopped. Roughing, finishing and different detail operations can therefore follow one another automatically within a prepared job.
Tool setter
Before the job, the magazine is loaded with the required cutters – such as long rasp cutters – and the tools are measured automatically using the tool setter.
The measured length of each cutter is stored in the tool database and remains available for future jobs.
The measured tools are therefore available for the current job and subsequent jobs. Especially for recurring parts, this reduces setup work and avoids unnecessary re-measuring.
Compressed-air monitoring
The GK Series monitors the compressed-air supply with a pressure sensor. If the pressure falls below the required level, the machine control detects it.
If pressure is insufficient, the machine stops automatically so pneumatic functions such as tool clamping or head swiveling never continue operating with inadequate pressure.
Automatic lubrication
The GK Series has an automatic central lubrication system. The relevant lubrication points are supplied automatically with lubricant.
You set the lubrication intervals yourself; the lubrication controller stores them permanently.
This largely eliminates manual relubrication and keeps the long guideways of the large-format machine reliably lubricated during operation.
Axis covers
The guides and drives are protected on all axes by bellows and covers. They prevent chips, dust and dirt from reaching the guideways, racks and spindle.
This protects the drive and guide components during continuous operation and contributes to consistent accuracy and a long machine service life.
Technical data
|
|
| Model | GK6030 |
|---|---|
| Clamping area L × W | 6.000 × 3.000 mm |
| Working height (Z) | 1.000 mm |
| Z-axis travel | 1.300 mm |
| 4th axis | Swiveling milling head, 180° |
| Milling spindle | 9 kW / 24,000 rpm |
| Tool changer | 10-position automatic |
| Compressed-air connection | 8 bar |
| Power supply | 400 VAC / 3-phase, 50–60 Hz |
| Footprint L × W | 8.000 × 5.000 mm |
| Machine height (operating) | 3.500 mm |
| Approx. machine weight | 3.500 kg |
| Technical data sheet | |
| Price excl. VAT | 78.500,00 € |
Scope of delivery
The GK Series is delivered as a 4-axis CNC gantry router prepared for commissioning. The machine, control system and basic machine equipment are included.
Included:
- GK 4-axis CNC gantry router
- Swiveling milling head
- Automatic tool changer
- Tool setter
- Machine table (steel profiles with aluminum T-slot profiles)
- Machine control
- Control PC package
- Machine software
- Automatic central lubrication
- Operating manual
- 12-month warranty
Options and accessories
The GK Series can be equipped with additional equipment and tools to suit the material, machining task and production environment.
Safety fence
A safety fence with safety door can be used to guard the large machine.
It prevents direct access to the large working area of the GK Series and is integrated into the machine control.
Safety light curtain
If open access to the working area is required, it can instead be protected by a safety light curtain.
If the protective field is interrupted during operation, the safety control stops the machine immediately.
Cutters
The appropriate cutters depend on the foam material, contour and block height.
Depending on the application, cutters with different diameters, lengths and cutting geometries are used – often large single-flute cutters for foam.
Additional tool holders
Additional ISO30 holders with ER32 collet capacity are available in different lengths, making it practical to keep several cutters permanently measured and ready.
Additional tool holders can be fitted with further cutters, measured and stored in the tool database.
Wireless handwheel
With the wireless handwheel – a cable-free manual control unit – you can move the axes directly at the block without returning to the control PC.
The handwheel lets you jog the axes manually, set the workpiece zero point and reference the machine conveniently – particularly useful on the large GK Series.
Commissioning, training and application support
Installation and commissioning
The GK Series is installed and commissioned by a cnc-multitool technician. Commissioning by the customer alone is not intended.
On site, the machine is positioned, leveled, connected and technically checked. Please note the operating machine height of approximately 3,500 mm. The machine control, axes, milling spindle, swiveling axis, tool changer and safety systems are then checked and tested.
Machine training
We offer machine training for the GK Series in Ilmenau.
The training covers machine operation, machine software, tool changes, tool measurement and the workflow through to completed machining. CAD/CAM software training is provided by the respective software supplier.
Application support
In Ilmenau, we can also work with you directly on specific machining tasks using the GK Series.
Materials, cutters, machining strategies, swiveling operations and parameters can be tested and optimized together on the GK Series.
Frequently asked questions
Does the GK Series have to be commissioned by cnc-multitool?
Yes. A cnc-multitool technician installs and commissions the GK Series. Commissioning solely by the customer is not intended.
What is special about the GK Series?
The GK Series is a large 4-axis CNC gantry router with a 180° swiveling milling head. The 4th axis can move simultaneously with X, Y and Z. This allows freeform surfaces to be machined with an adapted tool orientation, while sides, flanks and undercuts of large blocks can be reached without reclamping.
What does the 4th axis / swiveling milling head do?
The swiveling milling head can rotate the spindle through up to 180° and can be controlled simultaneously during machining. This allows the tool angle to follow the geometry; steep flanks, sides and undercuts become accessible without reclamping, and shorter, more rigid tools can often be used.
Is the GK Series a milling-only machine?
Yes. The GK Series is a dedicated 4-axis CNC router without an oscillating knife. Combined routing and knife cutting is provided by the W2 Series.
Does the GK Series machine sheets or blocks?
The main focus of the GK Series is on large blocks and bulky workpieces. It machines three-dimensional parts from foam and model-making blocks; sheets can also be machined when the geometry and workholding suit the machine.
Which materials can the GK Series machine?
Blocks made from EPS foam and PU/PUR foam, foam blocks such as upholstery and soft foam, and model-making/tooling blocks such as Ureol; PU-coated EPS parts can also be machined.
Can the GK Series machine EPS foam?
Yes. EPS foam in block form is one of the main materials for the GK Series, for example for large foam structures, models and large components.
Can the GK Series machine PU foam?
Yes. Rigid PU/PUR foam in block form is machined for dimensionally accurate patterns, molds and 3D models.
Can the GK Series machine metal or aluminum?
No. The GK Series is a CNC gantry router for foam and model-making blocks. Metals such as aluminum, steel and stainless steel are not machined.
Can the GK Series finish-machine coated foam parts flat?
Yes. PU-coated foam components, such as EPS parts with a PU coating, can be finish-machined flat and accurately to size on the machine.
What do customers produce with the GK Series?
Examples include large EPS structures, including PU-coated parts, foam furniture, transport and lightweight components, as well as patterns and molds.
What is the GK Series mainly designed for?
For 2.5D, 3D and simultaneous 4-axis machining of large foam and model-making blocks wherever freeform surfaces, sides, flanks or undercuts need to be machined in one setup.
How large is the GK Series?
The standard machine size is 6 × 3 m with a 6,000 × 3,000 mm working area and a working height (Z) of 1,000 mm. Larger and custom dimensions are available on request.
What is the operating height of the GK Series?
The machine height during operation is approximately 3,500 mm. This should be taken into account when planning the ceiling height at the installation site.
Are dimensions other than 6 × 3 m available?
Yes. We can manufacture larger working areas and custom dimensions on request. Contact us with your block sizes.
How is the block clamped on the GK Series?
The machine table consists of steel profiles with bolted aluminum T-slot profiles. The customer builds the required workholding on these profiles, for example stops, a fixture or a support; large blocks can be bolted, clamped, located against stops or bonded in place.
How fast does the GK Series machine?
Because of the large machine size, the machining feed is typically around 2–4 m/min; in practice the travel speed is around 20 m/min and speeds up to 40 m/min are possible. The actual feed rate depends on material, tool and contour.
Which milling spindle is installed on the GK Series?
The GK Series has an air-cooled 9 kW milling spindle with speeds up to 24,000 rpm and ISO30/ER32 tooling.
Which tool interface does the GK Series use?
The spindle uses ISO30 tool holders with ER32 collets.
Does the GK Series have an automatic tool changer?
Yes. The GK Series has an automatic tool changer; cutters are changed automatically within the machine program.
Which drives are used on the GK Series?
All axes are driven by servo motors with Yaskawa servo drives: X and Y use helical rack-and-pinion drives, while Z uses a ball screw.
Are the axes of the GK Series covered?
Yes. The guides and drives are protected on all axes by bellows and covers, keeping chips and dust away from the guideways, racks and spindle.
How is the GK Series constructed?
The gantry and frame use a rigid welded steel construction with machined mounting surfaces, designed for precise movement over a large-format working area.
How easy is the GK Series to operate?
Operating the machine itself is straightforward. The greater effort is generally in creating the geometry and CAM programming the four axes.
Which CAD/CAM software is required for the GK Series?
For 3D and simultaneous 4-axis machining, suitable 3D CAD and 3D CAM software with 4-axis support is required, for example SolidWorks, SolidCAM or Autodesk Fusion.
Which file formats are used for 3D models?
Three-dimensional models are generally exported as STP files, while freeform surfaces are often exported as STL.
What is a postprocessor?
The postprocessor converts the toolpaths calculated in the CAM software into the machine program for the GK Series, including swiveling movements.
How can the large GK Series be safeguarded?
Available safety options for the GK Series include a safety fence with safety door and a safety light curtain.
Can the GK Series be operated directly at the machine?
Yes, optionally using a wireless handwheel. It allows you to jog the axes, set the zero point at the block and reference the machine directly at the machine.
Is machine training available for the GK Series?
Yes. We offer machine training in Ilmenau covering operation, machine software, tools and workflow. CAD/CAM software training is provided by the respective software supplier.
How does the GK differ from the AC and W2 Series?
The GK is the large 4-axis CNC gantry router for blocks and bulky workpieces with a simultaneously controlled swiveling milling head. The AC is a 3-axis large-format CNC router for conventional 2.5D and 3D machining, while the W2 combines 3-axis routing with cutting using an oscillating knife.
What happens if service is required?
Our technical team provides support by phone and email and, for software issues, via TeamViewer – from machine software through to electrical and mechanical troubleshooting.
Are spare and wear parts available?
Yes. We supply spare and wear parts directly and at short notice.
Test your parts on the GK Series
Bring your parts, 3D data or material samples to Ilmenau and test the machining process directly on the GK Series. This lets you see not only the machine, but how your own application can be machined.
Together, we review part geometry, block size, accessible surfaces, suitable cutters and the required machining strategy. We also determine which machine size and equipment make sense for your production, including custom dimensions.
We can also define the appropriate safety equipment and cutter package for your application.
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