Crytur currently has two INTEGREX multi-tasking machining centers. “Given the need to machine a wide range of rotating parts with complex milling surfaces, this was our first machine for chip machining. With a counterspindle for part handover, we are able to machine the part in one set-up of the intermediate material, thus saving time and increasing production accuracy,” says Aleš Tuláček (left), CNC Production Manager at Crytur. Pavel Procházka from Yamazaki Mazak Central Europe continues: “The INTEGREX turning and milling center is one of our flagship machines for 5-axis machining, with extensive configuration options to suit specific customer requirements – from tool magazine size to clamping type, bed length to chuck sizes, and the ability to integrate automated part insertion and removal.”
Crytur from Turnov is a one-of-a-kind company worldwide due to its concepts. Under precisely defined conditions it grows artificial crystals, researched and developed in-house, which it then supplies after processing either as specific optical parts for further assemblies or directly as complete products.
In this complex production process, chip machining also plays a part, both of synthetic materials and of plastic, ceramic, and metal components subsequently assembled into final products. Mazak technologies are largely used for metal machining here.
According to company owner Jindřich Houžvička, there are very few companies in the world that can grow crystals, but their position is exceptional because they also have production technologies that allow them to produce and deliver more complex components than just a single crystal. “In addition to the actual growing and precision machining of the crystalline materials, we can also manufacture the necessary metal, ceramic, or plastic parts in our own CNC workshop, design and manufacture the electronic components, and finally disassemble, assemble, and package everything in a controlled clean room so that the final product cannot be contaminated by microscopic
impurities such as ordinary dust. In this, we are unique,” says Dr Houžvička with justified pride. Dr Houzvicka, with his team of more than 280 people maintain a tradition that began in the 1940s. Back then, a group of researchers were formed to verify the authenticity of gems, and over time they learned to produce these materials, exclusively found in the wild, in their laboratory. Thus, the production of synthetic crystals with significantly modified and improved chemical and physical properties compared to natural materials was initiated.
Precision and repeatability – the devil is in the detail
Metal fabrication and complete chip machining started in Crytur at the end of 2010. Until then, they only produced components from their crystals and had two CNC grinding machines just for grinding crystals and hard materials. Other components, such as plastic and metal parts, were produced exclusively in cooperation with others.
At the end of 2010, they also purchased their first CNC machine from Mazak, an INTEGREX with a MAZATROL Matrix system, and started chip machining. “For us, as beginners, it was a great challenge at that time and we spent whole days, sometimes evenings as well, at the machine,” recalls our host Aleš Tuláček, the CNC Production Manager here, who joined the company 15 years ago, and continues: “Over time, we mastered the problem and finally started to produce high-quality parts for assemblies We now have nine machines for chip machining and four machines for grinding. Mainly turning, precision turning of small parts, and milling technologies are involved.”
The requirements for quality and precision have also evolved considerably, along with the production structure. Precision is to the thousandth millimetre and the quality of the surfaces is microscopically checked during production. The entire range of products is partially or fully polished, which is also aided by the skilful hands of the laboratory technicians. It is undoubtedly primarily the result of the meticulous work and experience of the people, who love their jobs. People in this job have to think all the time, it is definitely not a routine operation.
We have had an excellent experience with Mazak and I would call the cooperation friendly. Our technologists and machine adjusters deal directly with Mazak technicians when problems arise, and we have experience with technicians arriving the very next day when quick service interventions are needed. I had the opportunity to visit Mazak’s production facilities in Japan in 2019, which was an unforgettable experience that confirmed to me that Mazak is a good choice.
ALEŠ TULÁČEK, CNC PRODUCTION MANAGER AT CRYTUR
The greatest value
Aleš Tuláček also faces the problem of a lack of qualified CNC machine operators. Crytur cooperates with the local secondary vocational school and the secondary school in Turnov. Fields of study taught include toolmaking, metalworking, and machining with a focus on CNC production. These students are also offered the opportunity to gain practical training in the production plant here. “However, education alone doesn’t play a big role in recruiting people for production positions. We have a lot of skilled people here who have studied or trained in completely different fields, and they are excellent workers,” says Aleš Tuláček. According to him, it is important to be willing to learn new things and to take them fully on board. Then virtually “anyone” can do the job. Life experience has shown him that if you are passionate
about something, you can achieve anything you want to.
Partnership the other way around
Their experience with Mazak technology dates back to 2010, when they invested in a Mazak INTEGREX 100-IVS machining center. Seven years later, they purchased a second INTEGREX i-100S already equipped with a Smooth X control system. In 2019, they expanded their machinery with three more Mazak machines – a QUICK TURN 100MY lathe, a VARIAXIS i-500 5-axis milling machine, and a VCN-530C 3-axis milling machine. For capacity reasons, the existing production premises became unsuitable, so new premises were built on the site of the former Preciosa grinding plant.
“This investment in new technologies was decisive in terms of which CNC machine supplier we wanted to continue to cooperate with and expand our equipment. We were deciding between Mazak and a Czech manufacturer. Since we were buying three machines at once, we had to address a number of requirements, both in terms of the machines and the parameters, as well as the quality of the service and the price. We had many years of experience with both companies. In the end, we decided on Mazak. If I had to make the same decision again now, I probably wouldn’t even consider another supplier,” says Aleš Tuláček, summing up his decision.
A promising future
Crytur currently receives a large volume of orders for similar types of products to those they currently manufacture. These include medical devices and equipment for checking chips in electric vehicles. And according to information from their customers, they should anticipate a further increase in order volumes. That’s why they want to continue to improve and expand on the technologies they already have. Therefore, according to Mr. Tuláček, they plan to expand their machinery again to increase production capacity. As they continue to grow rapidly, this theme goes hand in hand with improving the management of the entire production, the organisation of processes, and the workplaces themselves.
It is a pleasure to visit companies like Crytur and find the secret of their success. In this case, it is a complete production process of high-tech products of their own development, based on historical knowledge and experience, delivered to demanding customers in stable markets, withstanding cyclical economic fl uctuations. And when all of this is further enhanced by the partnership of suppliers in supporting production efficiency and flexibility, the equation always has a positive solution.
