Gallery

A Few Projects (updated periodically)

Insight's passionate crew of experts - are committed to foundational premise of true & absolute engineering excellence. The products and solutions are meticulously engineered and built to deliver uncompromising quality and superior performance, empowering manufacturers to achieve operational excellence.
Latest & advanced simulation and modelling tools are leveraged, whilst drawing from vast experience - to develop innovative designs that optimise productivity, efficiency and reliability. From component selection to advanced control systems, every aspect is engineered for holistic performance.
Quality is a non-negotiable at Insight. Rigorous testing protocols to identify and eliminate defects at every stage of the manufacturing process, ensure that every machine & solution meets the world-class standards of performance and reliability.
Continuous improvement is a way of life at Insight; Engineering DNA is to constantly seek ways to enhance the quality and capabilities of products, leveraging the latest technologies and best practices to drive innovation and stay ahead of the curve.
By combining precision engineering, innovative design, and an unwavering commitment to quality, Insight supports its valued clients across diverse industries to achieve excellence in their operations; Solutions are engineered to deliver superior performance, seamless integration, and tangible value to our clients, in every sense.

Insight Technologies, Galley of Products

iDrill DH Series, Gun Drilling Machine, Deep Hole Drilling Machine, Multi-spindle Drilling Machine, Long Hole Drilling Machine

iDrill DH Series | Deep Hole Drilling Machines

🔀 Gun-Drilling, BTA Drilling

👨‍🏭 A nuanced understanding of metal cutting mechanics, holistic process engineering, meticulous machine architecture, uncompromising build quality, and an undying passion for engineering excellence; that's how awesome metal-cutting machines are built! 🎯
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🔵 Here's an iDrill H500-8S [Horizontal 8-Spindle] Gun-Drilling aka Deep Hole Drilling Machine, installed at one of India's finest auto-component manufacturers! The machine is fully automated with Robot L/UL, and churns out a part every 12 seconds!

💡 A long drill is a cantilever, a vibrating element that's ready to go out of control at first contact with work-piece and during cutting as well!
Balancing vibrational characteristics & a clean force vector flow -whilst maximising cutting parameters to attain fastest cutting time, and as well -getting part quality in terms of - hole size, drift & surface roughness; all quite consistently, is something that warrants an in-depth comprehension of this critical process of producing long holes.
Deep Hole Drilling, is an art - that draws not merely from engineering expertise, but equally from extensive experience; Experience of knowing what works and what doesn't; How it does & how it doesn't!

✅ Insight's iDrill DH Series, is a modular set of finely-engineered pieces of equipment that personify process & machine robustness in all essence.
Meticulous build schema, nuanced architecture, design for long-life & top-notch performance -typify iDrill DH Series.

👀 Looking for Deep Hole Drilling Solutions? Let's discuss & set up some fine machines at your shop-floor!

iDrill Series | Multi-Spindle Machines

🔀 Drilling, Reaming, Boring, Tapping, Milling, and a host of operational possibilities!

👨‍🏭 Building state-of-the-art machines is not just another assignment for our engineers; it's pure passion for engineering finesse — the driving force to accomplish excellence in every nuanced way! 🎯

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🔵 Here's an iDrill 2W 8S [2-Way 8-Spindle] Machine, installed at one of the 'automotive component manufacturing' giants! The machine is 'Automation Ready' and produces parts at the rate of ~12 seconds/part.

💡 Multi-Spindle Multi-Station Machines are becoming the norm for high production environments these days, thanks to substantial savings in floor space, capital investments, manpower, and ease of automation. Gone are the days of installing a battery of GPMs such as VMCs or HMCs; manufacturers are now opting for compact yet high-production machines with the flexibility of reconfiguration.

✅ Insight's iDrills & iMCs fit the bill just right—offering the best of both worlds:
1. Takt of an SPM
2. Flexibility of a GPM

👀 Looking for productivity enhancements in the current lines, or a new high-volume production project is on the cards? Let's discuss, evaluate, and set up a smart production line (with a lot fewer machines!).

iCut Series: Modular & Configurable Circular Sawing Machines

Application spectrum for iCut is quite wide, from cutting of pipes & tubes, solid steel blocks, Cast-iron riser cutting, for making slots, slitting, fettling, trimming flash, cutting off risers & gates, and a variety of applications.
iCut series comes with Linear or 6-Axes Robots as well, with rotating tool on the Robot - for cutting/trimming/deburring of complex profiles. In some cases, the schema is inverted with component held by Robot and rotating tool on a spindle fixed to a station.

This one, iCut 2S GCM, is installed at one of the finest auto component manufacturers in the country!
This machine is meant for Riser & Gate Cutting; GDC, LPDC & HPDC Components.
-Fully automated with Robot L/UL.
-Gates & Risers are nicely separated from Chips, for quick re-melting & use. As the gates & risers are carried out of the machine, coolant is removed to a large extent, easing further processing.

And oh yes, these machines come with mist coolant as well, for further minimisation of coolant on gates, risers & chips.

iGring LG Series: Dual Face Fine Grinding Machine | iGrind LG720

Fine Grinding, also called Flat Honing, is the process that imparts high precision form (flatness & parallelism), tight size control (thickness) and superior surface finish.

Material removal is through the mechanism of 'abrasive sub-micro-grooving cum shear-abrasion', by the method of epicyclic-planetary feed - hence normalizing the surface to accomplish superior form, size & topography.
Surface topography is naturally an epicyclic cross-hatch, something that is desired for the kind of super-precision flat parts where's relative motion or need of face sealing - like the case of a valve plate.

And then, the use of super abrasive diamond / CBN wheels heralds long tool life and low CPC.

Moreover, the process is so clean relative to lapping, that the coolant is recycled & reused for extended periods, plus the finished parts are coated with a thin layer of coolant which makes post process cleaning extremely minimal or not at all.

iGrind LG Series, Insight's Dual Face Fine Grinding Machines, having been engineered to do exactly that - 'precisely & consistently', are a cross-over between Lapping & Grinding, offering the best of both the worlds-
- Accuracy of Lapping kinematics
- Speed & aggressive cutting of Grinding
[relative to lapping, Fine Grinding is 5 to 25 times faster, case-basis]

These machines, the iGrinds - though built for highly consistent super-finishing, can do roughing as well (removing say upto 0.6mm stock). Quite just like that(!) - thanks to the robust structural schema, thermo-symmetric design & force-vector-flow based element engineering.

With ingeniously & holistically designed 'Intelligent Controls' Architecture' with an empathic view of the end-use, running these machines in the shop-floor - is a breeze, quite literally!

Icing on the cake is - the cluster of smart algorithms developed by our Controls Engineers, which pretty much transform the machine into self-learning autonomy.

And then, state of the art build quality brought to life by our machine-tool manufacturing experts, carries these machines into a class of its own.

Hydraulic Fixtures, Machining Solutions, Cutting Tools, Fixtures

Tooled up Solution: End to End Turnkey

🔵 Components: Front Cover & Cover Plate (of Oil Pump Assembly)
- Hydraulic Fixtures, Tooling, Hydraulic Power units & Coolant Systems
- 4 Machines per Cell; 13 Cells installed
- Per Cell: 4 (2-1-1) Fixtures + Tooling set + HPP + Coolant System
[Front Cover 2xOP10 + 1xOP20/30-Unified] + [Cover Plate 1xOP10]

1️⃣ 3️⃣ [13] cells - installed & running - at one of India's largest precision component manufacturing groups!

🚘 These parts (different varieties) go into multiple car models of India's largest car manufacturer!
So, in a way perhaps - a large number of cars 🚙 are plying on Indian roads & abroad, with parts manufactured on Insight's solution lines; a matter of pride 😃 for our Tooled-up Solutions' team!

✅ Meticulous work-holding schema, systemic poke-yoke, easy changeover, ease of operator L/UL, automation readiness, high stiffness-to-weight ratio, ZDT design, are few of the typical features of Insight's Fixturing Solutions.

🔁 Tooling matrix & process architecture - that strike a refined balance of Quality-Cost-Productivity matrix (Q↑ C↓ P↑), is the mantra that our experts bring to life - through sound process engineering, and perhaps more importantly - drawing from vast experiences of having setting up 100s of Tooled-up solutions across a spectrum of industries and an array of varieties of components.

👉 'How you do what you do' makes all the difference!
When the motto is 'World-class, Nothing less', so is the outcome!

🙋‍♂️ Planning to set-up a new machining line? or expanding capacity? Let's discuss and hop onto an exciting journey of operational excellence - together!

iMC Series, Machining Center, Twin Axes, Metal Cutting SPM, Drilling SPM, Milling SPM

iMC Series: Twin Axes Machining Center with ATC

Here's another iMC M Series - a Modular Machining Center, this one being a Two-Axes iMC M-2X-C; just recently installed at a leading precision part manufacturer.
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While we're at it, let's see what's metal cutting & iMC series, is all about:

Metal cutting, an ancient craft with a history stretching back over 5000 years, has evolved remarkably in the last two centuries. As we moved closer to the 21st century, advancements accelerated, transforming this essential field. Yet, the science of metal cutting retains an air of mystery, partly because it hasn't received the intellectual investment it deserves. Despite this, a few trailblazers like Earnst & Merchant, Stabler, Lee and Shaffer, and Christopherson, Oxley, and Palmer have made truly remarkable contributions.

At the heart of Insight's prowess in metal cutting is a deep and nuanced understanding of its mechanics; basis of the fundamentals such as tool materials and geometries, shear mechanisms, chip flow, cutting fluids, thermal aspects, and host of critical elements & parameters that form the foundation of this complex science.

'iMC Series' is Insight's Machining Centers' product line - which flows into three solutions paradigms:
1) Standard Machining Centers: Personifying unparalleled accuracy, performance & reliability; Configurations of Vertical, Horizontal & 5-Axes Machining Centers.
2) Special Purpose Machines: Dedicated machines for specific purposes, especially for high production rates.
3) Customized Machining Centers: Cross-overs between General Purpose Machining Centers and SPMs (Special Purpose Machines). These offer a solution that strikes a balance between the flexibility of GPMs and takt of SPMs.

iHone VR-S Series: CNC Single Pass Honing Machine, VR500-6S

Building awesome machines, is an endeavour of passion, driven by the love of engineering, holistic application of science, and a 'no-compromise' attitude.

And our passionate crew of experts do just that!

Here's yet another iHone, VR500-6S, just recently installed at an appliances’ manufacturing major.

iMC H-Series: Horizontal Machining Centers | Modular & Configurable

In the ever-evolving landscape of manufacturing, 'precision and efficiency' have always been the cornerstones of excellence.

When it comes to metal cutting, behind every well-executed cut - lies a profound understanding of multi-disciplinary engineering sciences. It's not just about removing material; it's about doing so with a fine balance of QCD: Tooling, Vc, F, DoC, Fixturing 3-2-1, CPC, Time, the machine build quality and capability, and so much more! These must all align like a jig-saw puzzle - to sculpt the manufacturing excellence.

In this melee of interconnected arenas, the anchor is the machine in itself.
"The quality of the Machines on the shop-floor defines the boundaries of Operational Excellence."
Insight's iMC Series (the Machining Centers) takes on this role seriously, crafting machines that epitomize precision and reliability. From Force-Vector FEA to Topology Optimization, a host of scientific techniques - are harnessed to engineer and build the machines that excel in performance and durability.

Whilst standard models of iMCs personify absolute performance & reliability, what cranks these up a notch is the modular design of each module - whether it's the Servo-slides, Spindles, Structures, or the practical Guarding, catapulting the iMCs into a domain of hitherto-unseen facet of a balance between Flexibility (of GPMs) and Specialization (of SPMs), through a no-frills-design devoid of unnecessary complexity, whilst having been engineered for truly superior performance.

The next phase of Smart Manufacturing indeed hinges on the efficient use of resources - that strikes a neat balance of Q-C-D. And here's where the iMC Series of Machines - through their modular design, optimize space, labor, and costs, which in-turn enables the end-users to strategically invest into Automation, Industry 4.0 applications, and IIoT connectivity, creating a definitive smart manufacturing ecosystem.

iMC Series is envisioned and built to embody the transformational step into the future of manufacturing - an era of operational excellence - where precision, efficiency, and smart strategies converge.

Tooled up Solution: End to End Turnkey

🔵 Component: Crank Case (for Reciprocating Air Compressors)
🔵 Solution: End to End Turnkey; Tooled up Solution; 18 Fixtures; Tooling; Power units
- installed at India’s one of the largest conglomerates.

✅ Quick set-up change, robust yet compact architecture, clear force vector flow, ease of L/UL, intelligent 3-2-1, cutting force basis direct flow clamping & supports, build quality that lasts, typify Insight's Fixturing Solutions.

🔁 And then, comprehensive tooling engineering, in depth FEA, metal cutting schema & analyses, cost function minima, lean methodology, and an array of scientific tools & techniques are employed by our Metal Cutting experts, to derive an efficient process-flow that is consistent, reliable & robust.

Bottom line is, implement such solutions - that just run in the production, and don't stop!

🙋‍♂️ Let's discuss your needs and hop onto a journey of manufacturing excellence - together!

iMC Series: Twin Axes Machining Center

The trinity of metrics defines how a machine 'should be':
1] Quality 2] Throughput 3] Cost per component.
One affects the other, invariably. There's a fine balance to be extracted off this trinity.

Armed with the specialist expertise of Machine Tools, with over 20+ years of experience, Insight's machine tool engineers build best-in-class machines that offer just what is needed, keeping flexibility & operational excellence in mind.

Here's a case of an SPM built, but with flexibility. Installed at one of the world-leaders across a multitude of portfolios ranging from Marine, Navy, Transportation, Infrastructure Engineering, and what not!
The machine in the video - performs machining on over 18 variants of components.

Take a look at Youtube video and the description thereunder, for a deeper understanding of Insight's Custom Machining Centers - a cross-over between GPMs & SPMs.

Tooled up Solution: End to End Turnkey

Here's a set of Hydraulic Fixtures for the first of 6 lines in total (for now!), each line consisting of 3 cells, installed at one of the leading automotive component manufacturers' in India.

🔵 3 set-ups: OP10, OP20 & OP30.

➡ 2 Machines per cell:
↪ 1st for two OP10s on Pallet-A & Pallet-B
↪ 2nd for one OP20 on Pallet-A & one OP30 on Pallet-B

🔶 These lines being 'very high volume' production lines, 'the ask' was zero down time, near-zero part deflection due to Fixturing and the ability of the fixture to handle depth of cut of upto 5mm in rough milling; And that's a balance which only a design with meticulous engineering can strike!

🔁 Solution herein being end-to-end turnkey:
1) Fixtures, Tooling
2) Hydraulic Power-units, Tool Breakage Sensing, Probing
3) Comprehensive Line Prove-out, in terms of Cycle Time & Part Quality

🔆 Our crew of metal cutting experts, armed with over 25 years of extensive experience, specialise in comprehensive solutions’ implementation, from print to production - effectively providing one-stop solution for machining lines.
The team supports manufacturers from conceptualisation, to cycle time study, finalisation of process set-ups, choosing right VMCs, HMCs or other machines, and automation where truly necessary.
Well, this is just a snippet of what our Tooled-up Solutions' team does! In real, the team takes up the projects with holistic ownership - end to end!

🤔 Looking for metal cutting solutions? Let's get in touch, discuss and envision a high performing production set-up!

Gallery

A Few Projects (updated periodically)

iDrill DH Series | Deep Hole Drilling Machines

iDrill Series | Multi-Spindle Machines

iCut Series: Modular & Configurable Circular Sawing Machines

iGring LG Series: Dual Face Fine Grinding Machine | iGrind LG720

Tooled up Solution: End to End Turnkey

iMC Series: Twin Axes Machining Center with ATC

iHone VR-S Series: CNC Single Pass Honing Machine, VR500-6S

iMC H-Series: Horizontal Machining Centers | Modular & Configurable

Tooled up Solution: End to End Turnkey

iMC Series: Twin Axes Machining Center

Tooled up Solution: End to End Turnkey

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