By investing in a new machine for cutting and finishing, we are systematically expanding our range of services. For our customers, this means one thing above all: greater precision, greater flexibility and more options when it comes to bespoke requirements.
The new plant is not just a technical upgrade. It is also an important step towards further developing processes, using resources more efficiently and strengthening the SAGER site in the long term.
In this interview, our Head of Cutting and Finishing explains why this investment was important, which market demands are on the rise, and how our customers will benefit from it in practical terms.
Why did SAGER invest in the new machine?
“The investment in the new machine for cutting and finishing cannot be attributed to a single factor. Rather, it is the result of several developments that have gained significant momentum in recent years.”
A key issue is the increasing demand for precision and quality. Customers today expect clean cut edges, exact dimensions and consistently high-quality results. If existing technology can only meet such requirements to a limited extent or at great expense, further development becomes necessary.
Added to this is technological progress. Modern systems now offer significantly greater possibilities in digital processing, automation and repeatability. Processes can be controlled more effectively, data can be imported more directly and materials can be utilised more efficiently. It was therefore clear to us that if we want to continue offering our customers a strong range of cutting and finishing services in the future, we must keep pace with technological developments.
Another important factor is cost-effectiveness. Older machinery often requires more maintenance, carries a higher risk of downtime and uses materials less efficiently. Whilst a new machine involves an initial capital outlay, it can lead to lower unit costs, less waste and less rework in the long term.
The situation regarding skilled workers also plays an important role. Modern machinery with automated and digitally supported processes helps to reduce manual tasks and relieve the workload on staff in a targeted manner. This is particularly important in an environment where qualified specialists are a valuable asset and should be deployed wherever their expertise is of greatest benefit.
“At the same time, this investment forms part of our strategic development. It enables us to strengthen our operations, modernise our processes and lay the technical foundations to implement new products, materials and bespoke solutions even more effectively.”
Which market and customer requirements are currently on the rise?
“We have been seeing clear changes in the market for some time now. The growing demand for bespoke solutions rather than purely standard products is particularly evident. Customers are now increasingly looking for tailor-made formats, special contours, small batches or precisely tailored special solutions for specific applications.”
At the same time, expectations regarding short lead times and rapid response times are rising. Projects often need to be implemented more quickly, and changes sometimes only become apparent whilst the process is already underway. This requires flexible production capabilities that are not dependent on long lead times or additional tooling.
Demands regarding quality and repeatability are also on the rise. These days, a single good component is often no longer enough. What is crucial is that parts can be manufactured to the same standard in series production or when reordering.
Added to this are economic and sustainability considerations. Particularly when it comes to smaller batch sizes or bespoke products, solutions today must not only be technically sound but also efficient to implement. Less waste, efficient use of materials and reduced error rates are therefore key concerns for many customers.
Finally, digitalisation is also becoming increasingly important. Customers work with CAD data, technical drawings and clearly defined specifications. This gives rise to the expectation that this data can be transferred to production as directly and precisely as possible, without any unnecessary intermediate steps.”
What does the new machine actually mean for SAGER and our customers?
“The new machine in the cutting and finishing department represents a significant step forward for our department. It not only improves individual stages of the process, but also strengthens the entire process in several areas at once.”
Firstly, it boosts efficiency. Automated processes and faster processing times help to reduce turnaround times. This enables us to fulfil orders more quickly and respond more flexibly to customer needs overall.
On the other hand, it improves quality. Modern technology operates with greater precision and consistency. This results in clean cuts, fewer deviations, less waste and, overall, greater process reliability.
Another key point is the expansion of our range of services. The new machine opens up additional possibilities in terms of shapes, contours, materials and applications. This enables us to better meet new requirements and to expand our range of cutting and finishing services in a targeted manner.
In practical terms, this means the following for our customers: more precise and cleaner results, greater flexibility in terms of moulds and production volumes, faster order fulfilment, less coordination work, and cost-effective solutions, even for bespoke products and small batches.”
What can the new machine do?
“The machine enables high-precision cutting with tight tolerances and very clean cut edges. Even complex contours, cut-outs and custom shapes can be produced with precision.”
One major advantage is automation. Materials can be positioned precisely, machining processes programmed, and recurring jobs carried out consistently. This reduces the need for manual intervention and, consequently, potential sources of error.
Furthermore, the machine offers a high degree of flexibility in terms of materials and formats. It is suitable for a variety of materials and can efficiently process one-off items, small batches and repeat orders.
Digital control is also a key feature. Job data can be imported directly, making the process more precise and faster. At the same time, programmes can be saved and identical parts reproduced at any time.
Another advantage is material efficiency. Optimised cutting layouts and an intelligent arrangement of parts help to reduce waste. This improves both cost-effectiveness and the efficient use of resources.”
What types of processing, data formats and materials are available?
“The new cutting and finishing machine enables a range of processes to be carried out precisely and efficiently. These include, in particular:
- Contour cuts with precise outer and inner contours
- Cut-outs and openings, for example to accommodate specific shapes or technical requirements
The machine also offers a wide range of options in terms of data. Among other things, it can process:
- PLT / HPGL
- DXF / DWG
- AAMA / ASTM
- Gerber ISO
- CNC ISO
- CAD data from design software
This is particularly important because it allows digital templates to be transferred directly into production. This reduces the need for coordination, saves time and improves accuracy.
The new cutting and finishing machine is also of interest in terms of the materials it can handle. Among other things, it is suitable for:
- flat technical parts
- Prototypes and bespoke items
- Foams
- Insulation materials, such as glass wool and rock wool
- Paper, cardboard and corrugated cardboard
- Transparencies
- Rubber and sealing materials
- thin plastics, such as PVC or PET
- Softwood fibreboard
"This makes it suitable for a wide range of applications and opens up many possibilities for bespoke solutions, small-batch production and specific special requirements."
What are the main advantages over previous options?
“The key difference lies in the interplay between precision, speed, flexibility and digitalisation.”
Compared with manual or conventional methods, tasks can now be carried out much more efficiently. Complex shapes, smaller batch sizes or last-minute changes require less effort, as no additional tools or cutting dies are needed.
Another major advantage is the time saved. Automated processes shorten production times and reduce the amount of manual work required. This increases productivity whilst also improving reliability.
Material savings are also a key factor. Optimised layout and digital control help to reduce waste. This has a direct impact on costs and resource usage.
“Then there’s the versatility. Different materials and applications can be processed using the same machine. This gives us scope and increases our flexibility in our day-to-day operations.”
How exactly do customers benefit in their day-to-day lives?
“The new machine offers our customers very tangible benefits. They receive more precise, higher-quality and more bespoke solutions that can be implemented more quickly and cost-effectively.”
This is particularly evident in the case of precise dimensions and clean cut edges, recurring parts of consistent quality, last-minute changes or variations, small batches and one-off items, as well as bespoke solutions without costly tooling expenses.
Another advantage lies in the simplification of processes. If CAD or vector data can be imported directly, this reduces the need for queries and correction cycles. Reorders and recurring parts can also be reproduced more quickly, as existing data can be reused.
Overall, for the customer, this means: greater planning certainty, less coordination work and faster implementation of individual requirements.”
Which applications are particularly exciting?
“Applications that combine precision, customisation and rapid adaptation are particularly exciting. This applies above all to prototyping and product development.”
It is particularly advantageous in this context to be able to implement and test ideas without long lead times. Changes can be incorporated straight away, without the need to create new tools. This speeds up development processes and creates more scope for optimisation.
“However, applications involving small batch sizes, custom shapes or technical requirements are also exciting, as flexible digital processes create real added value in these cases.”
What is often underestimated in the market when it comes to cutting and finishing?
“People often focus solely on the actual cut. In practice, however, the added value lies in the entire process.”
For example, the importance of clean data is often underestimated. High-quality vector data and a clear technical foundation are crucial for a smooth production process. Errors in the source file can quickly lead to wasted time, quality issues and unnecessary effort.
The impact on overall costs is also often overlooked. It is not the cutting process itself that is the biggest cost factor, but rather inefficient processes, unnecessary waste, long set-up times or additional tools.
Furthermore, flexibility and speed are often given too little weight, even though they are a decisive competitive advantage for many customers today. The same applies to the ability to manufacture parts consistently and reproducibly to a high standard.
"Modern cutting and finishing are therefore not just a production step, but a key factor in ensuring quality, efficiency and competitiveness."
How does this investment strengthen SAGER as a business location?
“With this new cutting and finishing machine, we are taking a targeted approach to developing our site. We are modernising our production, expanding our digital processes and broadening our range of services in areas where the market today demands greater flexibility and customisation.”
For our customers, this means greater scope for bespoke solutions, faster and more reliable processes, consistently high and reproducible quality, reduced reliance on external service providers, and greater support with development, implementation and reordering.
"For SAGER, this investment is an important step towards further developing the site’s technological capabilities and strengthening our profile as a flexible, solution-oriented partner in the field of cutting and finishing."
What advice would you give to customers looking for bespoke solutions or specialised processing?
“Tailored solutions are much easier to implement today than many people realise. What used to be technically complex or economically challenging can often be achieved precisely and efficiently using modern technology.”
Above all, it is important to define requirements and expectations as clearly as possible. The better the starting point, the quicker and more smoothly the implementation will go. At the same time, we are happy to help our clients optimise their designs and develop a suitable solution.
“Individual requests are no longer the exception these days. With the right technology and the appropriate expertise, they can be fulfilled quickly, precisely and cost-effectively.”
Are you looking for a bespoke solution for cutting and finishing?
Then talk to us. We’d be happy to advise you and help you find the right solution for your project.