Zayer Thera W 26000 gantry milling machine: our second Zayer, added in 2020
Contents
Why the second Zayer followed the first
Three years earlier, with the Zayer Thera W 16000, we had brought the gantry design into our machining – and it had paid off: the machine was in demand, our customers' requirements kept rising, and component lengths grew with them.
In early 2020, the Thera W 26000 added ten metres of X travel, one metre of Y travel and 40 centimetres of Z travel compared with the W 16000. The second machine expanded the range of components that production planning could accommodate.
A gantry milling machine of this size is more than a catalogue purchase: the foundation, floor space and crane logistics have to grow with it. The investment shapes our production in Lorch to this day.
The Zayer Thera W 26000 in detail
The key data in direct comparison with its sister machine, three years older:
| Feature | Thera W 26000 (2020) | Thera W 16000 (2017) |
|---|---|---|
| X travel (length) | 26,000 mm | 16,000 mm |
| Y travel (width) | 5,000 mm | 4,000 mm |
| Z travel (height) | 3,250 mm | 2,850 mm |
| Table clamping surface | 26,500 × 4,000 mm | 16,500 × 3,000 mm |
| Milling head | 30°, positionable to 0.001° | 30°, positionable to 0.001° |
| Main drive | Heidenhain · 43 kW | Heidenhain · 43 kW |
| Control | Heidenhain iTNC 640 HSCI | Heidenhain iTNC 530 HSCI |
| Guideway | Roller way with adjustable preload | Roller way with adjustable preload |
The W 26000 offers 10,000 mm more X travel, 1,000 mm more Y travel and 400 mm more Z travel than the W 16000. This difference enlarges the working envelope; it is not a blanket commitment on component size or workpiece tolerance.
Two gantry milling machines: what they share and where their limits lie
Both Zayer machines use the same head principle and roller guideways with adjustable preload. The machines differ in dimensions and control. An NC program has to be checked for the respective machine configuration, tools and setup; identical head geometry does not mean a program can be transferred unchecked.
Two gantry mills allow orders to be allocated according to component size and available capacity. The smaller machine can take an order planned for the larger one when its travel, table area and tool access suit the component. Checking these conditions is part of confirming the delivery schedule.
Material certification and dimensional inspection answer different questions: an inspection certificate 3.1 describes the test results of the material; it is not a dimensional report of the finished machined component. The required documentation is agreed with the order.
What the expansion means for customers
With the W 26000, an X travel of up to 26 m is available. Unit weights up to 50 t and crane capacity up to 25 t are further key figures of our production. For bridge girders, machine beds and press frames, these limits are checked together with the setup; no single figure confirms feasibility on its own.
Cutting, welded fabrication, vibration stress relief and machining are all under one roof at Bock in Lorch. A welded assembly can move within the hall to the gantry mill. Production planning determines from the drawing which operations and intermediate inspections are required.
The investment in context today
This article was first published in February 2020 on our previous website. For the relaunch, we revised the text and checked the specifications against current machinery data.
Six years later, both Zayer machines are the backbone of our CNC large-part machining: together with the travelling-column milling centre, the boring mills and the vertical lathe, they cover machining from the compact housing to the 26-metre girder.
Together, the 2017 and 2020 articles show how the machining capacity developed in response to customer orders: first the W 16000, then a larger machine for longer and wider components.
The second Zayer in pictures
Revisit the workshop images from this article. Select an image to return to its chapter.
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The machine -
1 Why the second Zayer followed the first -
2 The Zayer Thera W 26000 in detail -
3 Two gantry milling machines: what they share and where their limits lie -
3 Two gantry milling machines: what they share and where their limits lie -
4 What the expansion means for customers -
5 The investment in context today
Frequently asked questions about gantry milling on the Zayer Thera W
What is the maximum component size that can be machined on the Zayer gantry milling machines?
The Zayer Thera W 26000 offers 26,000 mm of X travel, 5,000 mm of Y travel and 3,250 mm of Z travel; its table clamping surface measures 26,500 × 4,000 mm. These machine dimensions are not a blanket maximum component size. Clamping fixtures, tool access, unit weight and crane logistics are checked together on the basis of your drawing.
Does Bock offer gantry milling as contract manufacturing?
Yes – gantry milling is one of our core services in contract manufacturing: from the single large part to the ready-to-install assembly, on request including cutting, welded fabrication and painting from a single source.
What do two gantry milling machines mean for my delivery date?
Two gantry milling machines make it possible to allocate suitable orders by size and capacity utilisation. The W 16000 has shorter travels and a smaller table area; programs and setup have to suit the respective machine. Whether and when an order can run on the other machine is checked by production planning before a delivery date is confirmed.
Which materials are machined on the gantry milling machines?
We machine structural steel, fine-grain structural steel, wear-resistant steel and stainless steel. The material and the required certification are agreed with the order; an inspection certificate 3.1 documents material test results and does not replace dimensional inspection of the finished component.
Is an enquiry worthwhile for single parts or small batches too?
Yes – we manufacture anything from a single large part to a small batch, with no minimum quantities. What matters is not the quantity but whether geometry, material and deadline fit together; that is exactly what production planning checks on the basis of your drawing.
Standard for material certification
- Inspection certificate 3.1 for the material; not a dimensional report of the machined component DIN EN 10204 – Metallic products: Types of inspection documents
