MECAL FALCON

General

Engineered for uncompromising speed and precision, the Falcon stands as Mecal’s definitive High-Speed CNC Profile Machining Centre. It’s X-axis rapid speed runs at 150m/min (492 ft/min) making the Mecal Falcon the most performant CNC available on the market in its category. This 4-axis vertical spindle system is fully enclosed, designed not just for efficiency but for sustained, high-volume industrial production. The Falcon's robust design allows for versatile material processing, expertly handling aluminium extrusions, vinyl extrusions, light alloys, and light steel profiles, making it an indispensable asset for various demanding applications.

Equipped with an high-torque 8.5 kW, 24000 rpm electro-spindle and an HSK F-63 tool holder system as standard, the Falcon delivers exceptional cutting power and agility. Its integrated 10-tool magazine ensures continuous operation, with options available to expand tool capacity for even longer production runs.

This machine's sophisticated 4-axis configuration boasts a dynamic rotating beam with a robust clamping system. The A-axis, formed by the beam, provides an impressive rotation range of up to ±125° around the X-axis. This broad range, combined with ball-screw driven Y and Z axes and precision rack and pinion for the X-axis, ensures precise linear and circular interpolation on all three axes, enabling comprehensive machining at any angle on the workpiece.

Operations such as drilling, milling, and tapping can be executed swiftly on various faces of the profile. The Falcon also supports end-notching operations with a milling cutter, as well as an array of aggregates for working on component ends. Two standard pneumatically operated reference stops are strategically located at each end of the rotating beam, further optimizing throughput by enabling two-piece processing in one cycle and accommodating workpieces longer than the machine's stated capacity.

Clamping

The Mecal Falcon sets a new standard for material securing with its standard advanced self-motorized MMI clamps. These clamps are engineered for rapid, simultaneous, and independent movement to calculated positions, ensuring unwavering precision and security during high-speed operations. Furthermore, the MMI system's innovative MAM function allows for seamless clamp relocation mid-cycle, drastically reducing downtime and maximizing continuous production.

Programming

Programming the Mecal Falcon is as efficient as its performance, offering an intuitive and comprehensive experience. It utilizes “Mecal CAD/CAM3D” software alongside standard Mecal ISO programming, empowering users with advanced control. An optional STEP/IGES driver "CADLink" is available for seamless integration with third-party 3D design files, streamlining engineering workflow for peak high-volume output.

Features

• 4-axis servo control with absolute encoders – No axis referencing required.
• Ultra-high X axis rapid speed: 150 m/s
• Self-motorized rapid servo clamp positioning
• Automatic clamp repositioning within the cycle (MAM)
• Servo-driven rotating beam (A-axis) with integrated clamps for multi-angle machining.
• Precision clamp positioning on linear guide rails ensures accurate and secure holding.
• Dual-zone capability allows two parts to be machined in a single cycle, reducing tool changes and increasing efficiency.
• Supports end-notching operations on either end of the profile with a dedicated disc cutter.
• Pneumatic flipping stops ensure consistent positioning and fast setup.
• Central tool changer holds up to 10 tools; expandable with optional magazines.
• Minimum Quantity Lubrication (MQL) provides clean, efficient tool cooling.
• Automatic central lubrication for all guideways and ball screws reduces maintenance.
• Slick design with mobile control console
• Large front safety door offers clear visibility and full operator protection.
• Pre-configured for chip trays or conveyor to simplify chip removal.

Technical Data

• X axis rapid speed: 150 m/min
• X axis acceleration: 3.8 m/s^2
• Maximum Working Length: 4,013 mm (13 ft), including end milling
• Extended Machining Capability: Up to 8,026 mm (26 ft) using oversized part processing
• Spindle Power: 8.5kW
• Spindle Speed: 24000 rpm
• Tool Holding System: HSK 63F
• Tool Magazine Capacity: 10 tool
• Standard Clamp Width: 300 mm (10")
• Standard Number of Clamps: 5
• A-Axis (Beam Rotation): ±125° rotation around the X-axis
• Control Interface: Windows 10 based PC with 18.5” touch screen

Standard Equipment

• Electrospindle: air cooled, HSK 63F, 24000 rpm, 8.5 kW
• Magazine with 10 tools capacity
• 5 x Pneumatic clamps
• 2 x Reference stops
• Windows 10 based PC
• CAD/CAM 3D Graphic software with office licence

Optionals

• Upgrade to 8.5kW spindle with encoder for rigid tapping
• Additional MMI clamp, max 6
• Additional tool magazine, 3 seats on the RH
• Additional tool magazine, 3 seats on the LH
• Tool length measuring probe
• Work-piece touch probe
• Chip conveyor
• Inclined chip conveyor
• Chip bins
• Steel processing kit
• Sound insulation kit
• Bar code reader
• Integration with third party software
• CADLink 3D file convertor
• Various aggregates for milling, cutting or tapping
• Tailor-made tool kit