C.R. Onsrud 2016 CNC Catolog

MACHINING
CENTERS

The Onsrud Advantage

COMMITMENT TO THE FUTURE We continue to refine our production capabilities and field an ever-growing
line of high-precision CNC products. We have invested in superior service
capabilities, high-tech training facilities and an extensive applications
engineering department to further reinforce our pledge to provide the industry’s best
customer support.

The Onsrud mission is to bring our innovative, quality-assured and value-priced
machine tools to the worldwide marketplace.

We maintain accuracies within tenths of a thousandth (0.0001) of an inch, resulting
in precision that is not dependent on the ability to fit out-of-tolerance parts. The
accuracy is machined into each and every part.

With increased facility space, we are able to ship a variety
of machine models immediately upon order. Through a
worldwide network of factory-trained, full-service distributors,
Onsrud has built a framework to provide the industry’s most

committed service and customer support for each
and every machine we sell.

YEARS OF EXPERIENCE

In 1915 Oscar Onsrud and his son Rudy took the woodworking and machining
industry to a new level when they built the world’s first “Jet Motor” (air turbine) hand
router. Since that day, the Onsrud family has become synonymous with routing.
Virtually every aircraft built for the U.S. war effort in WWII had parts made on Onsrud
routers. Most of those machines are still in use today! Almost every M-1 rifle stock
built in the Springfield Armory was made on an Onsrud machine. It is difficult to walk
through any major furniture or aircraft plant worldwide without finding an Onsrud
machine in service. In 1976 our company raised the standard once again when Charles
Onsrud patented the “Inverted Router™”, an idea and a machine that revolutionized
the industry, increasing safety and usability.

Onsrud CNC Machining Centers began production in 1994 under the leadership of “Doing things better…by
Thomas Onsrud, our current CEO and head of engineering. Incorporating the same doing things differently.”
attention to detail and superior design standards as their predecessors, Onsrud -Rudy Onsrud circa 1950
utilizes the most technologically advanced components available, giving our
customers the highest performing machines in the industry at a price our competitors
say is just not possible.

Today our CNC routers and machining centers are revolutionizing the concept
of value by giving you the best-performing machines in the industry. Through
mass production and standardization, through modular construction and efficient
design, we can supply 4000 inch per minute (ipm) speed, the rigidity of cast iron
construction, “multi-drill” units, aggregates, saws, ‘C’-Axis and 5-Axis capability
with multiple spindles on the many frame designs we offer.

When the Wood Working Machinery Distributors Association decided to honor the The Onsrud family has
machinery manufacturer that most exemplified the type of company they wanted to been building computer-
represent, through quality and innovation, parts availability, overall value, and controlled Machining
customer and distributor support, they created “The Partner of the Year Award” in Centers for the aircraft
1994. Who won that very first Partner of the Year Award? C. R. Onsrud, Inc.! Yes! We industry since the late
have always done things differently and we are proud of it! That is what American 1950s. Since before many
leadership is all about! of our competitors were
even in business!
As always, our competitors will someday offer the innovations we have already
introduced, but you can have them today from C.R. Onsrud, Inc.

1

Engineering – Driven

FORM AND FUNCTION The top management people at Onsrud are engineers…not accountants trying to
cut corners. Onsrud employs more engineers per capita than any other CNC
Machine manufacturer. We are continually refining and re-engineering our
machines in pursuit of that elusive goal – perfection. At Onsrud, new machine
prototypes are assembled by the engineers who designed them. This streamlines
the manufacturing process and ensures that every product meets the designers’
hands-on requirements.

With every product we build, our engineers develop improvements, which are
then incorporated directly into the product line. In addition, constant
feedback from our customers provides information that helps us
continually improve our products. The close relationship between
engineering and manufacturing yields the most efficient machine
designs – reducing the number of components while improving
accuracy and simplifying service.

The same philosophy applies to our controls. We work very closely with
our control manufacturers to design and develop our own CNC that will run with any
hardware and software. This tight integration of programming and operating technology
has resulted in one of the easiest to use and most reliable control systems ever developed.

When you call Onsrud, you get a company that takes full responsibility for the entire machine.

“Perfection is FLOOR SPACE IS VALUABLE!
our goal... Excellence
There was a time when a fairly basic computer would fill a whole room! Today you can
will be tolerated” put a “Super Computer” in your pocket. Through efficient, ergonomic design, we have
packaged an awesome 4000 ipm performance into a machine that does not require a new
wing on your facility to house it. No one else offers a 5' x 10' split-table machine with full
table coverage that only requires a 8' x 14' footprint.

Our 5' x 12' split-table machine packs 4000 ipm, a 12-position tool changer, 15-spindle
multi drill, and aggregates with C-Axis into a similarly compact 8' x 15' footprint!

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Economies of Scale and Efficiencies in manufacturing save you money.

Doing Things Better By
Doing Things Differently

P ride and product go hand-in-hand at Onsrud. But building a machine the THE MANUFACTURING PROCESS
Onsrud way means much more than just meeting production goals and passing
inspection tests. Every Onsrud product must be ready to perform in the real
world before it leaves the facility – and the proof is in the cutting.

This quest for perfection is part of the ongoing dedication of everyone involved in Our price is always
the fabrication of Onsrud products, from the outside suppliers to the after-sale the “ten machine
support groups. price.” That is the way
they are built anyway!
The most important qualities of our assembly teams are their attention to detail
and their personal pride. All members are responsible for their own performance and
check their own work. This attention to proper fit and functional engineering
produces a consistent product that delivers reliable performance – year after year.

To further improve assembly line efficiency, new employees are trained in the
Onsrud way of building, no matter what prior experience they have had.

3

A Different Approach

QUALITY ASSURANCE Before leaving the plant, the typical Onsrud Router is subjected to hundreds of
quality assurance tests, including actual running time cutting parts while in assembly.
In fact, whenever a machine is not physically being worked on, it is running
pre-programmed tasks to check operational tolerances and performance parameters.

Quality assurance follows each individual part from initial fabrication through
subsequent installations. Static and operational testing continues as each component
subassembly is added, providing a paper trail of certification through the entire
assembly, testing and shipping process.

100% TESTED BEFORE SHIPPING

Onsrud uses state-of-the-art testing to check not only linear accuracy, but also
machine geometry. This ensures the three-dimensional squareness and accuracy of
every machine.

The machine is then put through a series of circular moves in the XY plane to
certify synchronous movement, then a series of moves in the XZ and YZ planes to
verify squareness.

At Onsrud, we not only build high-quality products, we provide the service, training
and support to keep them productive. Our high-tech design and manufacturing
operation is backed by a world-class service department. Our dedicated technicians
and engineers are fully prepared to help with all of your service, applications and
training needs.

Quality assurance Quality service continues in the field. To keep their skills and troubleshooting abilities
follows each individual sharp, all service personnel are required to visit our factory at least once a year for
hands-on training. Intensive courses in maintaining Onsrud machines, combined with
part from initial thorough testing, ensure the utmost competency of every technician. Once in the
fabrication through field, they stay connected via cell phones, laptops, PDAs and the Internet.

subsequent To ensure prompt service and minimize downtime, we maintain a large stock of service
installations. parts. With our network of distributors worldwide, you can be assured of a prompt
response to your needs. When you buy an Onsrud, you get more than just a machine,
you get a commitment to quality and service before and after the sale.

4

Commitment to Training and Support

Service is in the Details

INSTALLATION ONSRUD SERVICE ADVANTAGE

Included in the price is installation and training from an Onsrud factory technician
on your machine, cutting your parts, from your drawings, on your fixtures or
spoilboards, using your tools.

CERTIFIED TECHNICIANS

In addition to Onsrud’s technical team, each Onsrud distributor fields a fully-
staffed service department with factory-trained personnel. Onsrud owners receive
state-of-the-art service and support from both the factory and local level.

PARTS EXCHANGE PROGRAM We have built an elite
crew of service
Onsrud offers a core-rebate program that covers some major parts and components. technicians.
Onsrud will refund a percentage of the cost for a new part, once the old part has been
returned as a core, and determined to be able to be reconditioned. Additionally,
Onsrud believes that reasonably-priced replacement parts are all part of a machine’s
overall true value.

98% ON-SHELF PARTS AVAILABILITY

Because of our extensive inventory, when you order a replacement part, we can
usually supply it to you within 24 hours.

ONSRUD ONE-CALL SERVICE

Our One-Call policy provides expert service and a dependable, immediate response
to keep your machines running. Through our worldwide network of Onsrud Factory
Outlets and Onsrud Technical Centers, we have built an elite crew of service
technicians who focus exclusively on our machines. More than 98% of the time, our
technicians can successfully repair your machine on the first visit.

5

HSK-63F Spindle

HSK-63F Style Toolholder

(HSK-63A Style Also Available)

We use the most modern Onsrud HSK-63F Spindle Machines provide the torque and horsepower you need
HSK-63 spindle taper for heavy-duty material removal. Built using a heavily-reinforced, wide-stance
vs older ISO, BT, or base, cast iron columns and bridge, these heavy-duty machines provide the
solid foundation and rigid backbone necessary to take heavy cuts with large-diameter
CAT designs to deliver and long-length tools. Onsrud offers spindles that run up to 50 hp with high torque
heavy accurate cuts for those heavy cuts, yet can spin up to 24,000 rpm (30,000 rpm optional) for high-
speed work. The super-rigid headstock provides generous Z axis clearance.
with even the largest
diameter tools.

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Unlike many of our competitors, who
fabricate their spindle mounting plates
from aluminum, Onsrud utilizes a 1" thick
STEEL mounting plate which results in
greater machining accuracy and extended
spindle life.
A “Cartridge” type spindle - found on all
machines - provides numerous advantages
such as ease of maintenance and reduced
downtime. In addition, this system allows
for cost effective onsite replacements as
the spindle body can remain on the spindle
plate - eliminating the need for re-align-
ment

7

Whatever Your Requirements

Optional roller
hold down system
available on fixed
bridge and moving
gantry models

At Onsrud we not only Whatever your requirements,
build high-quality there is an Onsrud machining
center designed to meet
products, we provide them. Machine travels range from 72" x 61" x 11"
high-quality service. (xyz) for the small footprint 72C18, up to 1200" x 144" for
the massive 1200G25. And workpiece capacities run the
gamut, with our medium and large-frame machines boasting table
weight capacities over 1 ton. The range of capabilities for Onsrud Routers
is as varied as the machine capacities. Features include high-performance spindles with
standard speeds of 2,000-24,000 rpm, optional 30,000 rpm; and high-torque spindles
up to 50 HP!

The open-architecture Onsrud controllers make every one of our routers easy to
operate, easy to communicate with and easy to program. Onsrud controllers are built
with the operators and programmers in mind and are packed with intuitive features
you will not find on any other CNC machining center.

8

Onsrud machining centers include many standard features and capabilities typically There is an Onsrud
charged as extra cost options, if they are even available at all, on other machines. In Machining Center to
fact, many customers have saved hundreds of thousands of dollars buying an Onsrud. meet your every need.
Onsrud CNC’s can be customized with an extensive list of options, accessories, and products
that allow you to fully tailor your new machine to your specific application. Every Onsrud
machining center is designed to provide the features and performance that will make it
the best investment you have ever made.

9

Whatever Your Requirements
Onsrud Has A Solution

Whether you need a A t C. R. Onsrud, we build standard machines with standard options and
moving Gantry to cut standardized components. However, our standard lineup includes so many
12' wide by 60' feet machines, with so many options and components to choose from, we are able
to provide you with what seems like a customized solution without having to
long, or something engineer and build a totally tailor-made machine. After choosing a series and model,
smaller, Onsrud has a you can then personalize it with the options and table size to make it the exact
solution you need for your application.
solution for you.

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Our list of vacuum choices ranges from the standard C.R. Onsrud High-Flow Universal
Vacuum Table System, to the NEMI convertible grid table system, Schmalz Innospan, BVC,
dedicated spoil boards or fixtures, flow-through spoil boards, or even a full Schmalz
Movable Rail and Pod System! You can utilize almost any vacuum hold down system
available on the market today, and pair that system with any of our standard vacuum
pump options, or almost any other vacuum pump you prefer. If vacuum is not the right
solution for your product, choose from aluminum or steel t-slot tables or several other
customized hold down solutions.

As for controllers, your machine can be equipped with a very simple and easy to
use model like our B&R. Or you may instead opt for the more powerful OSAI or
FANUC controller. You can even choose to have a PC on the floor, no PC, or a PC front-
end controller.

Your standard And it does not stop there! You can choose from a complete list of Benz or Techniks
machine can be aggregates available direct from Onsrud, or any other brand you may prefer. You can
personalized to utilize your existing software, some other CAD/CAM package, or almost any design
your unique needs. software available on the market today. You can add perimeter pop-up positioning
pins to most models. You can choose from a variety of multi-drill heads, C-Axis
capability and so much more. With our revolutionary optional Factory Pre-Retrofit Kit
Option, you can even have many of our standard options added in the field later
without penalty.

With Our Modular Design

WE CAN USE ANY COMBINATION OF OUR MANY
STANDARD FEATURES TO OFFER UNLIMITED MACHINE
POSSIBILITIES AND CAPABILITIES!

INTUITIVE PC INTERFACE

All of the controllers offered by Onsrud offer an open architecture
Windows interface that will network easily right out of the box. All
of our controller offerings work seamlessly with ALL major CAD/CAM,
Design, Solid Modelling, and even product specific packages such as
cabinetwork, aircraft interiors, or stairs.

EFFICIENT DESIGN

When you look at the Onsrud router, you will find more uncluttered
room than any other machine in its class. There is plenty of room for
chips, with no hidden pockets or loose cables for them to build up in.
Vibration absorbing, non-conductive, phenolic machine tables, or more
traditional aluminum tables, are available on all models.

Standard
features offer
unlimited
machine
possibilities.

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Standard Features

SHIELDED CABLES

Onsrud uses only the highest quality shielded electrical cables, designed for the
constant flexing of cable-carriers, providing many years of trouble-free, continuous, multi-
shift production. Virtually all components are user-changeable with quick disconnects.

MASSIVE CAST IRON CONSTRUCTION

Cast iron is more expensive to buy and machine, but it provides up to ten times the
damping capacity of steel. That is why Onsrud uses cast iron on many models for all
major components that support the cutting spindle. Our castings are internally
reinforced with heavy ribs to resist flex and dampen vibrations, and every one is
thoroughly inspected prior to machining to ensure it is free of flaws.

WIDE-STANCE ONE-PIECE BASE

Our base is machined in one piece (after being stress relieved) to ensure machined-
in accuracy.

Get out your precision measuring device and check the dimensions and distances
between any bolts or critical machined surfaces. Also look inside the castings for
the heavy-duty, anti-flex, vibration-absorbing ribs that Onsrud adds. Now check the
competition – and you will find they just do not measure up to an Onsrud.

13

Standard Features

FAST, RELIABLE ELECTRONIC TOOL CHANGER

Our unique umbrella-style tool changer allows the operator to inspect or even
change any of the tools in the 12-position carousel while the machine continues to
cut your material. Some of our competition will tell you it is faster to carry the weight
and mass of the tool carousel with the spindle. Not so. With our faster acceleration
and deceleration, we can move the spindle back to our outboard tool carousel in less
time than you can stop the spindle rotation! Our competitors’ machines, which carry
the tool carousel with the spindle, require your operator to stop production in order
to check the tools. This also increases your maintenance costs by subjecting the tool
changer mechanism to the harsh environment inside the cutting envelope. With minimal
moving parts, the umbrella-style tool changer offers smooth, reliable action and long
life. This feature is not always found on competing products.

HIGH-SPEED BRUSHLESS MOTORS

Brushless motors are superior to brush motors in three distinct ways. First, standard
brush motors are limited in voltage and current values because of commutator limits.
The brushless motor can utilize twice the voltage and current, which means higher
speeds, faster acceleration and greater power.

Second, brush motors generate brush dust, which can lead to internal shorts and
accelerated brush wear. They also require periodic maintenance to
clean and replace the brushes. Our brushless motors have no
such problems.
Finally, on a brush motor, the armature, which contains the
heat-producing windings, dissipates heat very slowly through
the thick, permanent-magnet outer shell, dramatically
shortening motor life. As a result, current potential must
be limited to prevent burnout. With brushless motors, the
heat-producing windings are attached to the outer shell of
the motor, allowing heat to dissipate directly to the
surrounding air, resulting in a higher duty rating from a
more compact housing.

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Premium-quality ballscrews.

DOUBLE-ANCHORED BALLSCREWS Premium quality is the
only way to achieve
Onsrud uses only premium-quality ballscrews. Our ballscrews are anchored at both high accuracy.
ends and inspected for 100% parallelism to the axis guides. Pre-loaded ball nuts are
used to eliminate backlash.

HARDENED-STEEL BEARING PACKS

Onsrud uses hardened-steel bearing packs rolling on hardened-steel profile ways for
each axis of every router. Built using the same precision grinding technology utilized
in bearing manufacturing, these bearing packs feature zero clearance and full load-
carrying capacity in all directions. They consume less power, do not require any
adjustment and are proven to outperform sliding box ways for accuracy and speed.
Profile ways are used by every “high-end” machine tool builder today.

HIGH-CAPACITY CARTRIDGE SPINDLE

The advanced, four-bearing, four-pole, spindle design used for our HSK-63-F taper
spindles provides high radial thrust capability, yet generates minimal heat. We
accomplish this by finishing the front and rear bores of the housing and grinding the
OD of the spindle in one operation. This guarantees perfect alignment between bores
and ODs, thus reducing bearing heat.

Additionally, the two forward 50mm angular contact bearings are separated by a
10mm spacer to enhance radial stability – enabling heavy cuts. To ensure long life,
the spindle is pressurized with forced air to prevent contamination.

POWERFUL 12 TO 50 HORSEPOWER SPINDLE DRIVES

These top-of-the-line drives allow you to push the spindle to 150 percent of the
motor’s continuous horsepower for a full minute. That is more performance headroom
than any other drive on the market.

Premium components are more expensive, but it is the only way to achieve the high
accuracy and long life that our customers demand.

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High Rail Gantry Series

HR-SERIES The Introduction of the Five Axis High Rail Gantry Series machining
centers and mills signifies C.R. Onsrud's continued and growing
commitment to the advanced materials industry. The HR Series was
designed and built with a focus on the needs of manufacturers to produce
high precision non-ferrous, light ferrous, or composite products that
require a sizable working envelope to accommodate their large sizes or
awkward shapes. To this end; Finite Element Method design, and
Finite Element Analysis was performed extensively throughout the
design and engineering processes. Thus, you can be confident that
this machine will provide the accuracy, repeatability, speed,
structural rigidity, and high material removal rates demanded when
machining structural aluminum components, aircraft surface skins,
automotive molds, helicopter blades, plugs for boat molds, and
structured insulated panels just to name a few examples.

C.R. Onsrud High Rail Gantry machines feature a unique frame design that
specifically addresses the needs of non-ferrous metals, plastics, composites, and light
steel; whether wet or dry cutting. Two rows of heavy steel support pillars are joined
at their precision machined shoulders, forming support walls, onto which the X-Axis
guide ways and drive systems are mounted. A massive moving bridge featuring over

4-foot bearing spacing, spans
these stationary support
walls to form the Y-Axis.

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Electronically tensioned, dual synchronous direct drives on each end of this bridge allow for smooth, fast,
precise, and back-lash free motion. This design allows the electronics and mechanical drives to be located
completely outside of the machining envelope and prevents their potential contamination from wet or dry
machining. This design also eliminates the vertical pillars present in many other moving bridge machines.

Eliminating the vertical columns minimizes potential frame deflection or distortion,
and increases overall volumetric accuracy. This design also allows for the more

efficient and more rapid movements of a substantially larger and heavier
bridge; and for the use of a much taller and stiffer z-ram. A taller Z-Axis

cutting envelope is made possible,
and the machine is able to be more
rigid and more accurate at these
taller working heights.

Safety and usability have
always been hallmarks of Onsrud
machining centers. As a result of these concerns, side panels and doors completely surround the working
envelope to help ensure safe operation, reduced noise levels, and to control debris. When contamination
concerns are more critical, the optional retractable bellows roof can fully protect the surrounding
environment from fine airborne particulate or contamination. Also, there are optional lighting, down-draft
dust collection systems, and auger or conveyor systems, making it possible to better control and capture
most of the dust and particles. The roomy open design gives easy unobstructed access with a forklift or
overhead crane.

With our largest variety of options, sizes, upgrades, and possibilities, the flexible High Rail Gantry series
is built and engineered-to-order, around your products, your requirements, and your needs. The High Rail
Gantry makes use of the foundation and floor of your facility, to deliver the heaviest bed load capacities
available on any design. The floor inside the machine is left free and uncluttered, ready for any table,
tooling, fixture, clamping, or POGO part holding system. Various table options include Above Floor Roll-
In, Above Floor Fixed, Flush Mounted or Pit, Aluminum T-slot, Steel T-Slot, Drilled and Tapped, Slab Plate,
Magnetic, or Vacuum. Multiple spindle options range from higher RPM lower torque routing spindles to
lower RPM higher torque milling spindles with flood, mist, dry, or near-dry capabilities. Large capacity
automatic tool changers are available with HSK-63F or HSK-63A tooling. The High Rail Gantry is available
with open architecture controllers from OSAI or FANUC, to deliver the best 5-Axis machine motion and the
most programming capability and flexibility. Both available controller options include Tool Center point
Programming (TCP) and High Speed Machining (HSM) as standard. And, all of the controller options are
compatible with optional volumetric laser compensation and accuracy enhancing linear scales on all axes.

17

Compact High Rail

CH-SERIES The design of the C.R. Onsrud Compact High Rail Series machines specifically
addresses the needs of non-ferrous metals, plastics, composites, and light
steel; whether wet or dry cutting. The CH Series provides many of the same
advantages as our HR Series, such as a large volumetric machining envelope; but with
a much more compact footprint. It has the additional advantage of a self-supportive
one-piece design, that allows most sizes of this machine to ship fully assembled and
nearly functional; allowing you to be up-and-running, producing parts immediately.
The set-up and install are minimal because there is practically no assembly required.
The compact and sturdy design not only respects your expensive shop floor space, but
usually requires no additional floor preparation or modification potentially saving
unforeseen or costly integration and facilities costs.

This intelligent design begins with a stand-alone, machine base and foundation.
This heavy, one-piece thick-wall, engineered steel base with internal steel
reinforcements forms a machine bed that can easily handle the extreme weights of
large blocks of non-ferrous metal, over-sized tooling or fixtures for composites, and

sheet metal parts. The base also bears and strengthens two rows of
heavy steel support walls onto which the X-Axis guide ways and
drive systems are mounted. A massive moving bridge featuring
over three-foot bearing spacing
spans these stationary support
walls to form the Y-Axis.

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Electronically tensioned, dual drives Additional options available:
on each end of this bridge allow for • Complete enclosure
smooth, fast, precise, and back- • Lighting
lash free motion. This design • Down-draft dust collection system
allows the electronics and • Negative pressure
mechanical drives to be • Chip auger
located completely outside • Conveyor systems
of the machining envelope
and prevents their potential
contamination from wet or dry
machining. This design eliminates the
vertical pillars present in many other moving bridge
machines. Eliminating the vertical columns minimizes potential frame deflection or
distortion, and increases overall volumetric accuracy. This design also allows for the
more efficient and more rapid movements of a substantially larger and heavier bridge,
and for the use of a much taller and stiffer z-ram. A taller Z-Axis cutting envelope is
made possible, and the machine is able to be more rigid and more accurate at these
taller working heights.

You can immediately see the attention to detail, and how concerned the Onsrud
engineers are with safety and usability. As a result of these concerns, side panels and
doors enclose the working envelope to help ensure maximum operational and
environmental safety, reduced noise levels, and to control debris. You notice the
attention to detail when the doors open up far enough to provide full access to the
machine bed. When contamination concerns are more vital, the optional retractable
bellows roof can fully protect the surrounding environment from fine airborne
particulate or contamination. The roomy open design gives easy unobstructed access
with a forklift or overhead crane.

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Hybrid Mill Series
5-Axis Machines

H-SERIES ACNC machine tool that combines the best qualities of the CNC Router and the
F-TYPE CNC Mill, deserves it’s own unique classification. So, what is a suitable name
for this group of machines? Since it is more than a mill, certainly not just a
router, and does not fit into any existing machine categories or descriptions; the
Hybrid Mill creates a class all it’s own.

C.R. Onsrud, Inc. is proud to deliver a machine so powerful and elite, it deserves a class of its very
own. The Hybrid Mill simply brings all of the best production features of the CNC Router and the CNC
Machine Tool into one design. Wet or dry machining of composites, ferrous and non-ferrous materials
has never been easier or more cost effective than with the Hybrid Mill.

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It would be understating the Hybrid Mill to classify it as just an Elite CNC Router.
To start with, the Hybrid Mill boasts a much larger frame, wider bearing spacing,
heavier components, and tighter tolerances than are found on even the most “elite”
CNC Routers. Unlike Routers, the Hybrid Mill also comes fully enclosed and ready for
wet, dry, mist, or MQL machining with options for flood coolant either around the
tool, or through the tool. Like the Routers, Hybrid Mill boast flexible and innovative
universal vacuum part holding methods, quick set-ups and tear-downs, and very
attractive pricing. A Hybrid Mill also has options for t-slot tables, custom bolt
patterns, or steel tables. So, it delivers the part holding flexibility as a router, but
with the increased table load-bearing capability required for larger and heavier
work-pieces and tooling. With up to twin 33HP spindles, twin 24 position HSK-63A
dual arm rapid changers available, and a frame engineered to be large enough and
rigid enough to handle it all; a Hybrid Mill far exceeds the capabilities of routers.

But, just calling this machine a Mill, does not give you an accurate expectation of
its flexibility and capabilities. Mills typically have many limitations that by
design, a Hybrid Mill does not. Hybrid Mills are not limited by small table
sizes and restricted work envelopes. Twin tables with pendulum processing
for 100% spindle utilization are standard. Plus, the smallest table sizes
offered on a Hybrid Mill are over 5 feet by 8 feet with over 3 feet of Z
clearance. This provides a standard work envelope that is larger than what
would be optional on all but the most expensive of high end milling
machines. Mills are often characterized by their high torque, low RPM

spindles and their highly accurate but sometimes slow feed rates. Hybrid Mills
provide the High Torque necessary for machining all non-ferrous materials, advanced
composites, and many ferrous metals, but without sacrificing the high RPM’s that are
sometimes necessary for High Speed machining of aluminums, fiber reinforced plastics,
PVC, carbon fiber, graphite, a-cell, phenolic, and many more materials. Wet or dry
machining of composites, ferrous, and non-ferrous materials has never been easier,
faster, or more cost effective.

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Extreme Series 5-Axis
Fixed Bridge Machines

E-SERIES The Super Heavy Duty - yet super fast - 5-Axis Series CNC Routers carry the “No
F-TYPE Compromises” design of our Extreme Duty machines to the next logical, power-
production level. Ranging from the twin table, fixed bridge models of the HD
series to the moving gantry machines with super-large 15ft x 60ft fixed tables, you will
not find a heavier, faster, higher performing machine anywhere - at any price. On the
fixed bridge E-Series, Onsrud starts with the largest standard cast iron frame offered
anywhere in the marketplace today.

The cast iron bridge on the E-Series has over double the cast iron of even our
legendary C-Series models. The cast iron frame is then mated to our one-piece,
self-supportive, heat-treated, stress-relieved and normalized, internally-reinforced,

thick-walled, tubular steel base for unrivaled weight, mass, rigidity,
durability and super fast feeds and speeds.

All C.R. Onsrud 5-Axis machines have large vertical
rams and servos for fast positioning and
smooth cutting.

C.R. Onsrud 5-Axis machines are
faster, smoother and far more
rigid than our competitors’

comparable machines.

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Optional Enclosure

MOST 5-AXIS TYPE MACHINES COME STANDARD WITH:

• An OSAI Series 10/510i Controller with • Twin Tables or Twin Zones that can • 5-Axis Standard TCP
color touch screen PC Interface. operate simultaneously or independently • 5-Axis high-speed machining
• A 15HP Continuous Duty 4-Pole Liquid for continuous pendulum production. • Plus, all Extreme Series models can be
Cooled Main Router Spindle with up • 12 Position, Servo Controlled, Dynamic equipped with our revolutionary
to 25HP Rotationally Encoded, Liquid Rotary Automatic Tool Changer(s). Multi-Head, Dual Process technology.
cooled spindle options available. • Larger available table sizes: up to Twin
• Dual Arbor – Dual Support 5-Axis Router 12'X20' tables on E-Series, 12'x80' on
Spindle standard, instead of less rigid G-Series and up to 20'X100' on HR-Series
single arbor – single support designs.
• Up to an incredible 4000 imp
machining speed on E-Series and
2500 imp machining speed on G-Series.
• A Standardized modular design that
shares many of it’s parts, components,
and options with our 3 and 4-Axis
machines, to lower the cost of
manufacture without lowering quality.

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Multi-Head & Dual Process
Technologies

Choose multi-head 5-Axis Imagine that you could take the heaviest, fastest and highest performing machine
technology for the most available in the world at any price and then double its performance. What if
you could get the throughput of two complete machines out of a single machine
productivity a machine footprint? How would you like the flexibility of being able to run two completely
can offer-available on different programs at the exact same time on only one machine? Or to run two
identical parts at the same time?
all E-Series models.
With the optional C.R. Onsrud Multi-Head Dual Process Technology, you can do all of
this and more.

Start with any Standard C.R. Onsrud Extreme Series twin table model. Then add a
second tool changer, a second main router spindle and our optional Individual Servo
Control of Second Complete Spindle Slide from our list of available standard machine
options. When teamed up with the dual process power and capabilities standard in our
OSAI controller, you get our Multi-Head Dual Process Technology. Even additional drilling

or boring blocks, aggregate tool changers or
multiple C-Axis can be added as options. In
fact, this option is so flexible that the
two heads could even be configured
entirely differently!

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WITH DUAL PROCESS TECHNOLOGY YOU WILL BE ABLE TO:

• Use both heads on a fixed center • Use either head in a single process mode What if you could get
distance as a twin-head machine, working and fully cover both of the twin tables the throughput of two
on a single process (or part program). thanks to head collision avoidance which complete machines out
• Use both heads on a frequently is built into the logic of the controller. of a single machine
adjusting or varying center distance • Use the first head to machine one footprint?
working on a single process requiring process on the first table, while the second
different center distance. head machines an entirely separate and
• Use both heads on an alternating basis different process on the second table with
to perform different operations on a single thanks to built-in collision avoidance.
workpiece that may require numerous • Have the heads take turns machining
short or complicated operations and/or the same process in either single or
frequent tool changes. alternating table mode.

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Single Table Series 5-Axis
Fixed Bridge Machines

S-SERIES The 5-Axis Single Table Series delivers our best 5-Axis performance to value
F-TYPE relationship. The S-Series is designed for applications that require the
performance and accuracy of our popular 5-Axis Extreme Series, but are better
served by a single table machine layout. This makes our 5-Axis Single Table Series
the direct alternative to our twin table 5-Axis Extreme Series. These two series of
machines share many of their major components: from the control, to the electronics,
the mechanical linear motion systems, the tool changer, and even many of the
available options.

What differentiates the 5-Axis Single Table Series from the 5-Axis Extreme Series is
not in the components, but in the table layout. The S-Series design moves a single
table in the longer direction, so the bridge need only span the shorter dimension across
the width of the table. The shorter bridge has excellent leverage over the spindle and
magnifies the benefits of the fixed bridge, moving table design. This design also
employs fewer moving parts than many of the other possible machine layouts, which
can increase reliability and minimize potential downtime.

The main advantage of the S-Series design is the three-sided unobstructed access to
the table. This can be a significant material handling advantage for many applications
and products. Unobstructed table access makes loading and unloading of large
work pieces or tooling more convenient, and allows for the easy
integration of material handling systems, transfer

26

tables, robotic and other automation alternatives. Lastly, this
machine has a longer and more narrow footprint, which can
be the perfect fit in certain production settings, whereas
other designs may not as easily fit into the existing
production work flow.

27

Pro Series 5-Axis Moving
Gantry Machines

G-SERIES Onsrud engineers many of our frame components to be used cross-platform in
F-TYPE our 3, 4, or 5-Axis Models. By utilizing standard frames, parts and electronics,
Onsrud was able to leverage the economies of scale present in our 3 and 4-Axis
machine sales, and dramatically lower the overall price point of our 5-Axis models,
without compromising performance or value. For example, almost all of the parts on a
5-Axis Extreme Series are also used on the 3 or 4-Axis Extreme Series; and, many of the
parts on the 5-Axis Pro Series are also used on the 3 or 4-Axis Pro Series. Of course the
heads are different and the frames are taller and wider on the 5-Axis machines, but
the machine uses many of the same standard components, with the same off the shelf,
readily available, non-proprietary, and proven parts.

The one-piece thick-wall engineered steel base of the 5-Axis Wide Pro Series was
specially engineered with internal steel reinforcements. It is designed to handle the
extreme weights of large blocks of non-ferrous metal, large tooling or fixtures for
composites and sheet metal parts. You will be able to stack cut aluminum skins, or even
the large and thick assemblies we tackle in the RV, marine, and aircraft industries.
After being welded into a single structure, the machine base is heat treated and

slowly cooled to create a stress free, normalized and lasting
machining platform. Then the precision machining for all
of the critical components is accomplished in one set-
up, with all of the operations performed on the same
face, to guarantee machined-in accuracy and
stability. This base also incorporates the top-rail

28

design of the Pro Series which allows for shorter and
stubbier one-piece steel vertical columns, which are
more rigid and have more leverage over the bridge
than other side rail designs. Lastly, we use large vertical
Z-Axis rams with large bearing spacing for increased
rigidity, fast positioning, and smooth accurate cutting.
The result is a high precision machine that handles the
largest workpieces, and the heaviest materials and
tooling, offers unique automation and material
handling options, and provides the best possible
cost per table size relationship available.

If you do not have unlimited time to wait for your machine to finish, and are picky about
your part’s fit, and finish then do not just buy the cheapest 5-Axis Machine you can find.
Be more demanding, and expect the highest possible accuracies, at the fastest feed rates
that the tooling can sustain, without chatter, or melt back all over a part. With a little
research, you will find that Onsrud offers an incredible 5-Axis value for the performance and
capability the machine delivers. Investigate for yourself how our philosophy of standardization
allows Onsrud to offer custom-sized large-format moving gantry 3, 4, and 5-Axis CNC Routers
at standard machine prices, with the reliability and parts availability of standard machines.

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Extreme Series 3 and

4-Axis Fixed Bridge Machines

E-SERIES Designed and built to be the heaviest, fastest, and highest performing machines
available in the world at any price, the Onsrud Extreme Duty Series CNC Router
Our heaviest, best and is truly our “No-Compromises” model. We start with one of the largest standard
fastest “Flagship” machine frames offered anywhere in our marketplace today. The bridge on the E-Series
machines. has over double the machine frame of even our legendary C-Series models. The bridge
and vertical columns are then mated to our one-piece, self-supportive, heat-treated,
stress-relieved and normalized, internally-reinforced, thick-walled, engineered steel
base for unrivaled stiffness, mass, rigidity, durability, feeds and speeds. We then use
only the highest-end, top-shelf, non-proprietary and
readily available components in the world today
to offer you, the most technologically advanced
Onsrud ever. Many of the standard features
on the Extreme Series may be options
and/or upgrades on our other C.R. Onsrud
models, but they are not even offered by
the competition.

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When you require unrivaled feed rates,
machining speeds and rapid traverse rates,
when your jobs demand the ability to run the
largest diameter tool and take the deepest,
heaviest cuts in the most dense
and unforgiving materials, when
you insist on the highest possible
accuracy and repeatability, when
you want the best possible machined
finish that tooling can provide... if you want the
lowest operating maintenance cost, the lowest number of occurrences and the shortest
duration of downtime... when you want to have the assurance and satisfaction of knowing
beyond a shadow of a doubt that you have purchased the biggest, heaviest, best built, fastest,
most powerful, most durable and most productive machine available on the market today, then
the C.R. Onsrud Extreme Series is for you.

ALL EXTREME SERIES MACHINE MODELS COME STANDARD WITH:

• An OSAI Series 10/510i Controller with • A 18HP Continuous Duty 4-Pole, • 12 Position, Servo Controlled,
Aggregate Ready, Dynamic Rotary
color touch screen PC Interface. Reversible, Main Router Spindle with Automatic Tool Changers.

• Optional FANUC 31i Controller system up to 50HP liquid cooled available • Larger available table sizes up to Twin
8'X12' tables and over 8'X24' overall.
with PC interface spindle options.
• Optional revolutionary multi-head,
• An incredible 4000+ ipm Dual Process technology, available on
all Extreme Series models.
machining speed.

• The extra large frame that it

shares with our 5-Axis models.

• Twin tables that can operate

simultaneously or independently.

Designed and built to be
the heaviest, fastest and
highest performing
machines available in the
world at any price.

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Super Duty Series 3 and
4-Axis Twin Table Machines

C-SERIES At Onsrud, Super Duty means cast iron. It also means the spindle travels the
stationary bridge along the width of the tables while the tables pass
underneath the bridge along their short dimension. This design (like our
moving gantry design) only uses half of the floor space that a long single moving table
design would use. Its design is extremely efficient, shuttling the twin tables for
continuous production and 100% cutting time. With this design, the CNC’s table can
be loaded and off-loaded without interrupting the cutting and production that is
occurring on the other table. Its heavier and thicker cast iron frame tends to naturally
absorb or dampen any cutting vibrations.

When you look at an Simply put, cast iron just has a better ability to absorb and dampen cutting
Onsrud CNC machine, vibrations, while steel tends to amplify and transmit these
oscillations to the rest of the frame. When you are
you will find more cutting man-made materials most of the time, a
uncluttered space than heavy, tubular steel frame, like our Panel Pro
Series is acceptable. But, if you intend to cut
any machine in primarily solid wood or non-ferrous metals, which
its class. There is creates significantly more vibrations, then you will
plenty of room for definitely want the additional dampening ability of a cast
chips, with no hidden iron frame, such as the Onsrud Super Duty Series. You will quickly
pockets or loose cables find that the cast iron frame design will not only contribute to the
for them to build up in. overall weight, mass, and rigidity of the machine, but will also promote faster
feed rates, better finishes, longer tool life and less maintenance. A cast iron frame
design will usually cut much deeper per pass and machine much faster while maintaining
a better finish. It will simply out-produce all other designs and make more money for
you in the process. Take a look at the most expensive and productive model offered by
any “high-end” CNC router manufacturer. It will almost always use the same cast iron,
Twin Table, Fixed Frame design as the C.R. Onsrud Super-Duty series routers.

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A Twin Table, Cast Iron
Fixed Frame Design.

33

Single Table Series 3 and
4-Axis Fixed Bridge Machines

S-SERIES T he Single Table Series is designed for applications that require the fixed bridge
performance of our popular Super Duty Series, but are better served by a single
table machine layout. This makes our Single Table Series the direct alternative
to our Super Duty Series. These two series of machines share many of their major
components: from the control, to the spindle, the electronics, the mechanical linear
motion systems, the tool changer, and even many of the available options. Thus, they
are both very comparably priced, and offer very similar performance and value.

What differentiates the Single
Table Series from the Super Duty Series is not in its
parts or components, but in its table layout. The S-Series
design moves a single table in the longer direction, so the bridge need only
span the shorter dimension across the width of the table. The shorter bridge has better
leverage over the spindle, is more rigid, and magnifies the benefits of the fixed bridge,
moving table design. This design also employs fewer moving parts than many of the
other possible machine layouts, which can increase reliability and minimize potential
downtime.

34

The main advantage of the S-Series design is the three-sided unobstructed
access to the table. This can be a significant material handling advantage for many
applications and products. Unobstructed table access makes loading and unloading
of large work pieces or tooling more convenient, and allows for the easy integration of
material handling systems, transfer tables, and other automation alternatives. This
design also works very well with Roller-Hold-Down systems for stack cutting of multiple
whole sheets of material. Lastly, this machine has a longer and more narrow footprint,
which can be the perfect fit in certain production settings, whereas other designs may
not as easily fit into the existing production work flow.

35

Pro Series 3 and 4-Axis
Moving Gantry Machines

G-SERIES A “Moving Gantry” CNC router, when made correctly, is particularly well suited
for panel and sheet processing applications. Here, the table stays fixed, while
Panel processors the bridge moves over its surface. This design saves valuable floor space,
love the flexibility keeps the price down, allows for useful options (such as tool changers and multi-
spindle drilling heads) and offers incredible throughput and productivity. This design
and production is not normally as well suited to the heaviest cutting and highest material removal
capabilities that rates because moving steel frames, on any CNC router design, have a difficult time
absorbing many of the additional cutting vibrations created by the heavier
the Panel Pro applications. However, if it is built and designed correctly, like our Pro series, it can
design offers. easily break down full sheets of 1-1/2" thick plywood, laminates, veneers, or 1/4"
thick aluminum jig plate, at super fast feed rates, under continuous duty conditions
and handle heavier applications on a limited or
multi-pass basis.

Check out the 20' x 100' bed mills used in the aircraft
industry and you will find the same Hardened and
Ground Precision Helical Rack, Dual-Drive system
used exclusively on the Panel Pro moving
gantry router. Dual-Drive costs us more, but it
will not twist under a load the way a single
center-mounted ballscrew or cantilevered design
does.

Panel processors and cabinetmakers love the flexibility and
production capabilities that the Pro Series design offers. Sign makers
and plastics fabricators typically like moving gantry machines because of
the lower initial purchase price, while solid surface and aluminum sheet
fabricators like the large table-size-to-cost ratio.

36

37

Wide Pro Series 3 and 4-Axis
Moving Gantry Machines

G-SERIES Experience has taught us that
W-TYPE table size equals flexibility and
that lack of table size always
means limitations. That is why the
Wide Pro Series offers some of the
largest table sizes available. Tables are
offered up to 12 feet wide and over 40
feet long as standard sizes; with
custom table sizes that are available
at over double our standard lengths.

38

The Wide Pro Series can guarantee that the available machining envelope will not
have to be the limitation in your CNC Machining operation.

The one-piece, thick-wall steel base of the Wide Pro Series was specially
engineered with internal steel reinforcements. It is designed to handle the
extreme weight of large blocks of non-ferrous metal, oversized tooling or fixtures
for composites, and sheet metal parts. You will be able to stack cut aluminum
skins, or even the large and thick assemblies we tackle in the RV, marine, and
aircraft industries. After being welded into a single structure, the machine base
is heat treated and controlled cooled to create a stress free, normalized, and
lasting machining platform. Then the precision machining for all of the critical
components is accomplished in one set-up, with all of the operations performed
on the same face, to guarantee machined-in accuracy and stability. This base also
incorporates the top-rail design of the Pro Series which allows for shorter and
stubbier one-piece steel vertical columns, which are more rigid and have more
leverage over the bridge than other side rail designs. The result is a high
precision machine that handles the largest workpieces, deals with the heaviest
materials and tooling, offers unique automation and material handling options,
and provides the best possible cost per table size relationship available.

39

Tech Series 3 and 4-Axis
Moving Gantry Machines

T-SERIES We have learned that when end users install a CNC Router in their shop, many
will soon base their entire production and their company’s livelihood on that
machine. Above all, when designing the Tech Series, C.R. Onsrud decided that
we would not cut any corners, or make any compromise that would result in a CNC Router
with which you would not be confident in. There are many shortcuts we could have taken
to make a machine that could sell for a cheaper price, but would just cost you more
money down the road. If a machine is down an extra time or two per year, has to wait
for parts instead of producing them, does not last, or simply can not do what you bought
it for, all because it was built to a lower standard, any initial savings disappear in a
flash. With its world-class support and unusually low
operating maintenance cost, the Tech
Series will not end up being any more
expensive than the lightweight,
intermittent duty, heavily discounted,
entry level machines.

A well built and The Tech Series was designed and
reliable production built to be a lower cost alternative
duty machine at an to our most popular Pro Series,
without many of the compromises of
affordable price. entry level machines. The Tech Series
frame has been designed and checked
with industry leading ANSYS FEA
software to ensure the most rigid design in
its class. The Tech Series is built with a one-
piece, self-supportive, heat-treated, stress-relieved
and normalized, base for unrivaled weight, mass,
rigidity, durability, feeds and speeds at this price
point. The Tech Series also employs the same dual direct
drive, dual support, closed frame and moving gantry design as our
Pro Series, instead of the single drive, single support, cantilevered,
unsupported, open-ended design found on many entry level machines.

40

The Tech Series is designed with a 12-position hide away rack style tool
changer, to allow easy access from all 4 sides. In order to save cost, the Tech Series

has less available optional equipment than the Pro Series. We have trimmed away
some of the extras on the Pro to make the Tech Series, without compromising the
capability of the machine to perform, or to last and produce. After all of the
trimming, we were left with an excellent, cost-effective CNC Router that we are still
proud to call an Onsrud. If you do not require the increased throughput and capacity

of our larger Pro Series, Super Duty, Single Table, or 5-Axis Series machines, but
you do not want to base your company’s future on a toy, then this is
what you have been waiting for.

41

M-Series 3 and 4-Axis Moving
Gantry Machines

M-SERIES The C.R. Onsrud M-Series CNC Router is an “All Onsrud,” No Compromises,
attractively priced solution for the demanding wood, plastic, aluminum,
composite, and non-ferrous materials producer or fabricator. The user
friendliness, compact design, ease of access, and straightforward connectivity of this
model make it the first choice for a variety of industries. This model is designed with
a smaller table size and a more compact footprint for the company whose budget or
floor space may be limited, but their production needs and expectations are not. In
fact, this model shares so many components, features, and design characteristics with
our larger premium models, that there was debate among our engineers, whether it
should just be a smaller model within an existing series. On this No Compromises
machine, the only thing you will find trimmed away… is the price.

The M-Series is proudly designed and built, from start to finish, in Troutman, North
Carolina, USA, by a Privately Owned American Company. Just saying “Made in the USA”
is not enough. Some other companies believe that just final assembly of their Chinese

made or European made frames and sub-assemblies in an empty warehouse, or in the
corner of some building here in the USA, qualify their machine as “American
Built.” Those companies may
even be owned by Asian or

42

European conglomerates, but still eagerly slap a “made in USA” sticker on their
products. The M-Series starts with a steel frame that is designed, created, heat
treated, fabricated, and precision machined right here in the USA. There are inevitably
some components on our machine that must be sourced from the top vendors outside
the USA, in order to produce a product with the highest quality, utmost reliability and
maximum performance. But, all assembly and production, of every C.R. Onsrud machine,
happens from start to finish at our state of the art manufacturing facility in the USA.

Do not let the attractive price or the compact footprint deceive you. The M-Series
is definitely All Onsrud. It delivers the impressive Onsrud performance, 100% steel
construction, and a long list of standard features and available upgrades, which our
customers have come to expect. There are even several sizes to choose from, ranging
from 4' X 8' and up to 2M X 3M. Plus, the M-Series includes the exact same factory
provided onsite machine training, 5-years of advanced technical support with online
remote diagnostics, 5-years of 24/7 Emergency Tech Support, and the same 2-year
warranty package that comes standard on any Onsrud premium machine offering.

43

No-Sweat Nesting

C .R. Onsrud is proud to offer a Fully Automated and Cost Effective Nested Based
Manufacturing solution. This system is available on any M-Series, Tech Series,
or Pro Series CNC Router equipped with Onsrud’s standard B&R
control system.

No Sweat Nesting begins with Onsrud’s Premium Fully Automated Material In-feed
System for the loading of full sheets of Plywood, Melamine, or other similar
man-made sheets over ¼ inch thickness up to 1" thickness, up to 250 lbs each.
Operators need only use the forklift to load an entire bunk of material on the Tech
or Pro Series or a Half Bunk on the M-Series and then press the ready button to begin
running programs. The system will load the CNC Router’s vacuum table
accurately, without operator input or intervention, and then begin the machine cycle.
System features heavy duty welded steel frame, Auto Indexing scissor lift material
load table, and Heavy duty welded steel squaring posts. System uses the common
electrical and mechanical linear motion systems that the CNC Router uses and
the entire system is run from one B&R CNC controller.

This In-feed System is available with or without material pre-labeling. The
available Auto Pre-Labeling System will print and place labels on the sheet
using the same axes motion as the panel loader, while the sheet remains on
the bunk, waiting to be loaded, and then machined. Auto Pre-Labeling
does not add any additional footprint or cycle time, but it does add to
efficiency and minimizes potential for operator errors by pre-labeling
the parts before they are even loaded or machined. This system

44

requires external labeling software. Currently this system can be run from Planit’s
Cabinet Vision, Cabinet Ware, SigmaNEST by SigmaTek, RouterCIM by CimTech, or
CabinetMaker by Microvellum.

No Sweat Nesting is designed to include the Automated
Nested Sheet Offload System with Integrated Dust Extraction
and Integrated Conveyor Out-Feed Table. Now, the system can
automatically remove any finished parts, scrap, and all dust and
debris from the machining area in under 25 seconds. The out-feed
tables are available for up to 5’X12’ sheets. A Material Removal
Scraper-Arm with Integrated Dust Extraction Hood, uses the same
dust collection that is provided to the main router spindle to clean the
table after parts are machined. Pneumatically controlled table side-guides rise to
assure that your already machined parts and scrap transition smoothly to the included
auto-indexing offload conveyor table and then aid in the positioning of
the next sheet of material along with the included pneumatically controlled pop-up-
positioning pin. A dust extraction grate is located at the table’s transition which

collects loose dust and debris as the sheet
transitions from the machining
area to the offload table.

45

Pod and Rail

A nother innovative offering from C.R. Onsrud is Pod and Rail part holding technology.
These machines utilize a special, purpose-made, engineered steel frame, based on
the proven design of the Pro Series. This modular design enables us to offer Pod and
Rail part holding technology over a more extensive range of machine lengths and widths,
in 3, 4, or 5-axis. A dual-drive, dual-support frame is rarely found on pod and rail machines.
Using considerably larger support columns delivers improved rigidity, higher machining feed
rates, and increased Z-Axis clearances. The open design of the machine base allows scrap
or debris to fall harmlessly away from the work piece, and is configured for use with an
optional integrated waste-removal conveyor system. Electrical cabinets located on the back
of the bridge reduce the size of the external energy chain, and allow the operator
unrestricted loading or unloading from either side of the machine. The machine is more
readily accessible, and has a greatly reduced shop footprint. For customers with
exceptionally high production demands, the machine can be configured for pendulum
processing, with two completely independent work zones of rails and pods. While processing
parts in one zone, the operator could be loading or unloading the other zone - resulting in
100% spindle uptime.

Our engineers tailored the Pod and Rail machine frame to accommodate large linear
profile guide-ways to bear the non-proprietary Schmalz Vacuum Support Rails and Pod

46

system. Instead of the smaller and less rigid round guide rails that many of our compeditors
use. A simple push of a button pneumatically unlocks the rails for quick and precise
positioning. Vacuum Pods can then be clipped on and off of the machine in seconds,
allowing for extremely quick setup. Large retractable part alignment stop-blocks are located
at the end of each zone, and each rail, for reliable part location. Each rail can be equipped
with material handling rollers which keep the work piece elevated so that the operator can
more easily position the pods, beneath the work piece. Optional longitudinal lift-rails can
be incorporated for convenient side loading the machine - providing the operator with
greater flexibility for getting their raw material and parts into position.

This unique Pod and Rail system can be combined with our High Flow Vacuum Table
and/or Vacuum Grid Convertible Table to create a flexible, multi-purpose solution.
The versatility of this "mixed table" configuration is unsurpassed. It will allow long parts to
span across both zones; or can be used for pendulum processing of dissimilar products.
Setup, changeover, and tear-down times could all but be eliminated. With these two part
holding technologies combined on the same machine, the flat table portion could be
equipped with a flow through spoil board for panel processing or nested based
manufacturing. Alternatively, it could also be used with the full compliment of Nemi,
Schmalz, or BVC Cups, pods, pins, and fixtures. Customers with a wide range of machining
applications will no longer be forced to choose one design or the other.

47

Roller-Hold-Down (RHD)

C . R. Onsrud, Inc. offers a specially designed CNC manufacturing system for the high
volume production of stacked sheet materials. The Onsrud Roller-Hold-Down (RHD)
option is intended for furniture frames, marine plywood parts, high volume nested
based manufacturing, Starboard, or stacks of thin plastic sheets, just to name a few. C. R.
Onsrud Roller-Hold-Down machines provide the ultimate flexibility for routing single sheet,
stacked sheets, or parts with a surface area too small to be held with vacuum alone.
They deliver the capability and throughput of multiple CNC machines for the cost and
footprint of only one machine.

Onsrud RHD machines feature 4 rollers, with 2 retractable rollers on each side of the
cutting spindle(s). These rollers are located both on the leading edge, and trailing edge,
of the cutting spindle. The rollers automatically extend and retract immediately before
rolling off the edge of the cutting table, preventing accidental movement of the top sheet,

by the rollers. Having either too much, or too little, downward roller pressure could
result in parts not holding down correctly. Each roller's downward pressure can be
regulated to the optimal setting for maximum holding efficiency, which avoids
premature wear and prevents "slamming" of the rollers into the table and
material. Many other RHD systems require the operator to "prepare" the
sheets by screwing them together prior to the machining process, but
Onsrud Roller-Hold-Down machines are
engineered to prevent additional cost-added
steps like these. This option is perfect for
holding down warped sheet stock and
stacked sheets, but sometimes certain

48