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Rising production volumes demand automated processes: shot blasting and mass finishing in military vehicle manufacturing

Defense and dual use: established technologies entering new territory Armored personnel carriers, main battle tanks, and specialized vehicles such as armored recovery vehicles and combat engineering vehicles must withstand extreme operational stresses. From the drivetrain and running gear to large-scale structural assemblies, every component contributes to the reliability of the overall system and to the safety of the crew – this calls for a perfect surface quality that meets the specific requirements: it is a decisive factor in resistance, service life, and functional integrity under the most demanding conditions.

GKN Aerospace Relies on Rösler’s Mass Finishing and Shot Blasting Solutions for High-Precision Turbine Blade Processing

For decades, the area around San Diego (CA) has been a center for the US aerospace industry. It offers highly qualified personnel as well as a large network of suppliers. At the same time, the state of California is imposing strict regulations for sustainable and resource saving manufacturing. In 2024 GKN Aerospace, a globally leading manufacturer of high-performance components and systems for the aerospace industry, who supplies customers like Pratt & Whitney, General Electric and Boeing, opened an ultra-modern factory in El Cajon. This location specializes in MRO operations (Maintenance, Repair and Overhaul) for all kinds of aircraft components. The high environmental protection standards in Southern California are in perfect synch with the sustainability offensive of GKN Aerospace. But for suppliers they can pose a real challenge: Every piece of equipment must comply with the strict environmental standards in the state of California. But in addition, it must offer precise, reliable and highly productive performance. For the relatively complex reconditioning of turbine blades for aircraft engines the customer chose high-performance surface finishing systems from Rösler, not only for stripping of the used turbine blades but also for the final mass finishing operation. To a large extent this decision was influenced by the positive experience the GKN Aerospace sister company in Malaysia had with comparable Rösler equipment and processes.

The versatile possibilities of surface finishing for firearms using mass finishing

The importance of surface finishing in firearms manufacturing Surface finishing occupies a central position in the manufacturing of firearms. Many components, such as slides, frames, barrels, magazines, and small parts, are produced from steel or aluminum, typically by milling, and exhibit burrs, machining marks, surface roughness, and sharp edges after the cutting process. These must be removed or smoothed without compromising tight dimensional and form tolerances.

Machine insight: Rösler RMBS Engine Block Blast Machine

The Rösler engine block blast machine RMBS is a turbine blast machine developed specifically for the machining of engine blocks. Its defining feature is the manipulator clamp developed exclusively by Rösler, which securely grips workpieces and moves them in a controlled manner throughout the blasting process. This enables reliable machining of even complex geometries and hard-to-reach interior areas.

Cooperation between Orchid and Rösler creates perfect synergy for precise finishing of orthopedic implants

For ten years Orchid Orthopedic Solutions (now part of Tecomet), one of the world’s leading contract manufacturers of orthopedic implants and medical instruments, has been relying on state-of-the-art finishing equipment from Rösler. To replace manual surface finishing operations with automated treatment systems, the company has been using Rösler drag finishers and high energy disc systems at three locations in the United States and Great Britain. With impressive results: Significantly reduced cycle times, consistently high finishing qualities and absolutely repeatable surface finishes – irrespective of location, working shift or equipment operators. Today, the partnership between Orchid and Rösler is a shining example for efficient, scalable and easy-to-validate surface finishing processes in medical engineering. It is living proof that effective technical cooperation can create tons of added value.

面向医疗技术的表面处理

医疗技术领域中，仅仅好并不足够。假肢、矫形器、植入物和医疗设备必须完美，并满足最高要求。德国医疗技术协会对其进行了如下定义，应该 “拯救生命，帮助治愈并提高人们的生活质量” 。并且，该行业迫切需要创新的解决方案，尤其是在表面处理方面。究其原因，医疗技术设备通常仍然通过人工（即手动）的方式进行平整、打磨和抛光处理。因其用于人体和体内敏感区域，所以对表面质量和匹配精度的要求达到最高程度。同时，需求也在不断增长，如果没有智能、自动化和经济的解决方案，就很难满足这些要求

Surface Finishing of Orthopedic Implants – Critical for Function, Service Life, and Patient Safety | Part 1

Orthopedic implants are among the most demanding products in medical technology. They permanently replace damaged joints, perform complex biomechanical functions, and must simultaneously meet the highest requirements in terms of biocompatibility, wear behavior, and dimensional accuracy. Accordingly, precisely coordinated surface finishing throughout the entire manufacturing process is of great importance, as the functional performance of an implant is largely determined by its surface. This is exactly where automated mass finishing and blasting processes come into play.

Efficient cleaning of ammunition components in mass finishing systems

The production of ammunition for sporting, hunting and military applications is extremely energy- and resource-intensive. From circular blanks to cups and deep drawn casings and ultimately to the finished cartridge consisting of the bullet, propellant charge, primer cup and ignition components, the work pieces, primarily made of bras, undergo numerous annealing, deep drawing, forming and machining operations. What all these manufacturing steps have in common is the use of process aids such as coolants, lubricants and oils. In addition, oxide residues are generated and must be removed from the work piece surfaces after each processing step. Only this ensures reliable downstream processing. Properly prepared surfaces after each drawing stage help prevent defects and cracks during subsequent forming operations. Drying technology also plays a crucial role, ensuring a stable, stain-free and metallically clean surface condition.

Cost-effective surface finishing of acetabular cups in a rotary vibrator - digitally controlled and highly precise

Most suppliers still prefer CNC-based technologies for grinding and polishing the internal surface areas of acetabular cups. However, a mass finishing process in a rotary vibrator, in combination with a specially developed clamping device, now represents a substantially more cost-efficient solution. The process is not only less costly, but it produces the required surface roughness values easily and consistently. Rösler Oberflächentechnik developed a 2-stage process that allows the simultaneous finishing of up to 35 cups. This became possible with a specially engineered work piece fixture.

Shot blasting solutions that are faster, more effective, more flexible and create less wear

When it comes to refining the surface of castings and improving their performance characteristics, shot blasting is one of the most important treatment technologies. The broad equipment and blast turbine portfolio and comprehensive service package of Rösler is intended to meet the increased demands for product quality, productivity, cost-efficiency and sustainability. State-of-the-art shot blasting methods are as important as innovative casting methods.