In 2012, 3Form Inc. became a $100m company. Centrally located in Salt Lake City, they are a power house in the glass and plastic lamination industry. To service their customer’s needs and designer’s imaginations, they need A LOT of different interlayer laminates.
They are also committed to providing custom products, engineered solutions, and a best-in-class “green” foot print. This meant they need a laminate cutting solution that minimizes waste, improves operator efficiency, and can work with their wide variety of materials. This solution also needs to work with their existing 50′ long wall-of-material roll holders. The solution was a rolling vacuum table and a Carlson Design plotter/cutter.
The Carlson cutting system was an ideal choice. It is light enough to roll, robust enough to run two or three shifts, simple enough for anyone to operate, and we are dynamic enough to work with their custom “home built” table and programming needs. Oh, and it’s all at a price that can’t be beat! After the first month they reported: “The cutter is working awesome. Everyone, from the guys cutting the material, to the guys using the material loves it.” -Joseph Taylor, Sampling/Inventory Manager – Jan, 2014.
The PTi is our most industrial model plotter/cutter, designed specifically for cutting heavy laminates, working in an industrial environment, and operating 24/7 with little or no maintenance. The PTi features a 3X stiffer gantry, 2X larger Y & Z motors, and 33% more powerful X motors with load support wheels to reduce wear. This is the toughest, simplest, most rugged, and most affordable large bed cutting system on the market.
Before we arrived, they built an 11ft steel table frame on wheels. The table has a 50′ long run, and can slide from rack to rack.
Here is a one minute video demonstration of cross cutting 96″ long sheets of .015″ PTG laminate: https://vimeo.com/84319271. Using the PTi-72 to cross cut is similar to their old solution of slitting.
If they wanted to cut a 71″x39″ rectangle out of 60″ wide material, how would they do that? Before, they would cross cut the roll 71″ long. This would go to another department for trimming. With the Carlson, cutting parts to size is a no-brainer. Here’s a video of that 71″x39″ cut: https://vimeo.com/84311596.
The real savings come when they start quickly generating and nesting custom parts. Our software has a built in rectangle maker and free CAD program for custom pattern creation. It can also import *DXF CAD files or import a list *.CSV file format. For simple shapes our manual nesting program is quick and easy to use. More complex shapes or larger quantities of patterns can run through our autonesting program.
For custom parts and smaller pieces, nesting can result in big savings. We’ve seen anywhere from 15-35% savings in the glass lamination industry. In the following video we cut over a dozen pieces in two minutes. Our nesting software virtually eliminates any scrap. Our optimizer further saves time by eliminating redundant cut lines. The result is a fast, efficient, and waste free cut that is very, very repeatable: https://vimeo.com/84316733. After cutting, parts are placed in labeled racks before being wheeled to layup.
This is a great system for cutting interlayer and we look forward to reporting future success. We would like to give a big THANK YOU to Joseph, Tommy, Mike, Sam, Enrique, Alex, as well as Jeff and Tom from the maintenance department. If you are interested in learning more about how we setup their cutter, trained their personnel, or just seeing more plotter/cutter pictures, then please keep reading!
We are going to review the installation and training. Most of this will be explained by pictures and captions, making it easy to cover a lot of ground in a little time.
Your plotter/cutter is now installed! Now begins setup, pattern creation, and training.
We were thrilled to work with such a dedicated team. These guys worked hard to integrate a new piece of equipment into their workflow. We are glad to hear it’s all thumbs up!