When DATRON designed the core architecture of their machines, they opted for what is now known as the DATRON polymeric concrete table—a slab made from polymeric concrete (also known as resin concrete). This composite material combines polymers with sand and gravel, offering high dimensional stability without the heavy weight typical of traditional cast steel tables. It also provides low thermal expansion and vibration-damping benefits. This corrosion-resistant surface aligns with DATRON’s philosophy that machines don’t need to be heavy and massive to machine intricate aluminum or non-ferrous parts precisely. Although granite was a viable option, it is more costly, heavier, and lacks the thermal expansion advantages of polymeric concrete. The composite material is cast into a mold and sets like traditional concrete, but this process can result in a non-flat surface that is difficult and expensive to grind flat or true.
Reinventing Workholding: The Challenge That Sparked Innovation
This apparent challenge became an opportunity for innovation—leading to the development of a groundbreaking fixture and mounting system that has transformed workflow and job setup for thousands of DATRON users. This system is regarded as one of the best features associated with owning a DATRON.
How DATRON’s Conical Mounting System Ensures 3-Axis Accuracy
The development of DATRON’s conical mounting system was directly shaped by the design of the polymeric CNC table, which required a creative workaround to achieve three-axis accuracy. They would cast stainless steel mounting posts slightly above the table surface with threaded mounting holes before pouring the polymeric concrete. After the table was set and mounted within the machine, the posts would be machined parallel to the Z-axis, creating an accurate surface for mounting the workholding. However, because workholding plates typically require oversized holes for adjustment, repeated tramming (alignment) in X & Y would be necessary for each setup—something DATRON aimed to eliminate.
DATRON devised the final innovative system featuring stainless steel cylinders cast flush into the table to achieve this. These stainless-steel pads would then have a 45-degree conical feature machined into the stainless-steel cylinder by the actual machine.
This conical form allows a matching male conical component to register precisely in all three axes (X, Y, and Z). Because the conical shape was machined with the constructed machine, this ensured an exact setup in all three axes. A threaded M6 hole in the pad enables the mounting of quick-change pallets, jigs, or fixtures, either purchased separately or custom-made. These conical parts can also interface with T-slot tables or vacuum fixtures.
Quick-Change Workholding on the DATRON Polymeric Concrete Table
This system allows users to place a fixture plate onto the table that automatically aligns perfectly in the X, Y, and Z directions. Securing it with screws is all that’s needed; once set, the fixture remains accurately aligned for future use, eliminating the need for repeated tramming. Many customers attach their workpieces or fixtures directly to these plates, confident that their accuracy is maintained throughout production.
Further streamlining, DATRON developed a vacuum system that secures workholding plates without screws. During manufacturing, vacuum ports and feeder lines are integrated into the polymeric table, allowing users to engage or disengage the vacuum with the simple push of a button. This system provides quick, precise mounting—within microns—and facilitates faster setup times.
Step-by-Step: Installing DATRON Conical Inserts for Precision Setup
Installing the conical inserts is straightforward: reverse mount your fixture or work plate and machine a grid of 14mm diameter holes at 100mm centers by 7mm deep. If done correctly, the conical insert should press-fit into the milled hole. Loctite® can be used if the insert is too loose or is falling out. Properly installed, the fixtures should sit slightly above the table surface, ensuring accurate registration via the conical system. For screw mounting, drill 6.5mm diameter through holes at each conical insert location.
Smarter CNC Setups with Camera-Based Work Offset Recall
Another innovation is DATRON’s approach to storing and recalling work offsets. The machine’s control software uses the built-in camera to capture images of each setup, allowing operators to select and recall precise fixture positions later easily. This visual system simplifies workflows, minimizes errors, and reduces setup time—making repeat production faster and more reliable.
Design Innovation Driven by Engineering Constraints
When engineers or designers face adversity or roadblocks during the design process, the outcome can sometimes be revolutionary, with improved solutions over traditional methods. This could not be truer in the case of DATRON using the polymeric concrete design for their machine construction. Overcoming the challenge of not having a perfectly flat machining surface created the opportunity to reinvent how workholding can be mounted to a machine table that improves accuracy, reduces mistakes, and is more efficient than mounting systems found on traditional CNC machine tools.
