Step by step to perfection Just good or absolutely perfect? TRUMPF application consultants are fully aware of the subtle difference. They apply expertise and insights to identify potential for improvement.

Ulrich Brändle and his Application Consulting colleagues will find the right solution for any customer problem.

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Step by step to perfection

There are quite a few parameters you can play around with on the road to a perfect part. TRUMPF’s Application Consulting experts will be pleased to show you what they are.

Ulrich Brändle and his colleagues are never really satisfied until they have checked off the last item on their list. A completed checklist means that yet another customer can now produce goods better and more efficiently. “There’s a difference between simply making a part and optimized manufacturing,” he says. As coordinator he, together with his colleagues of TRUMPF Application Consultants, makes certain that production is always up to snuff. “We want to help our customers work with our machines at the highest possible degree of perfection.” That is the objective the Ditzingen specialists have set for themselves.

Our machines have a significant number of features and, at first, people working with new technologies tend to recognize only a few of the opportunities that are actually available to them. TRUMPF’s experts will help users discover the world beyond standard functions.

Competent help during start up

No two machines are alike. That is why customers receive support – right from the beginning – with assistance to show them how to deal with complicated technologies such as automated bending or using a combination machine. Once a machine has been installed, the customer receives instruction on how to use it and, after initial training, will be able to gain experience on his own. A few weeks later a TRUMPF consultant will show up to help again.

Individual advice

The team will always come up with tricks and tips on how to solve individual problems – regardless of the machine or technology involved. They will have an answer on how to obtain a perfect seam with a suitable punching tool, how to set the right parameters for a certain material, and even how to select the operational sequence when punching. The questions the team receives are as varied as the technologies themselves, which is why it is so important to clarify exactly where intervention is needed. That is why TRUMPF always checks the prevailing conditions in detail during the start up phase. What do the machine’s surroundings look like? What options does the machine have to offer? What sheet metal thickness is it to be used for? And specifically, where is the exact problem?

Before application consulting starts, the item about operator training levels has to be checked off. The one-week basic training program at TRUMPF is an absolute must because Application Consulting is not a substitute for training. After all, advice given to customers on their own premises is always specific to concrete cases and issues, meaning that it deals with fine tuning and finding room for improvement. This is why customers are always asked in great detail about their expectations – before the consultation process begins. Before the technicians depart, they check to see whether all of the questions on the list have been checked off.

The right partner

Once all of the requirements and general conditions have been clarified in the start up phase, TRUMPF’s Application Consultants will select, from a central pool, a suitable specialist for the customer’s needs. Which technology is needed? Is it going to be necessary to help out with programming or with machine operation? Or maybe both? At the end of the day, the customer is going to be satisfied only if all of these factors have been taken into consideration.

Consultants frequently visit customers who work with combination machines. This technology offers a wealth of benefits and thus great potential for improvement. Selecting exactly the right tool is just one of the things that TRUMPF’s consultation experts can help with. Tool sequencing, sheet utilization, and implementation strategy all offer additional room for improvement. Although all of these points are covered during the basic training course, the application specialists are best able to solve a customer’s immediate problem on site. In spite of the standard procedures, every customer has his own special parts, with specific dimensions and geometries that he must pay attention to. This also demands a high degree of flexibility on the part of the consultant.

Better to work together

Another benefit of giving advice right at the machine is that you can also support employees from other areas. Normally only programmers attend the training course, but at the customer’s site the production manager might drop in or a designer might ask the consultant what he thinks of a certain part. This is how best to utilize synergies because efficient processes and perfect components can best evolve if everyone involved knows what is feasible. “In this respect, close cooperation between the programmer and operator is critical,” states Brändle.

Occasionally, even fundamentals have to be questioned and TRUMPF’s specialists give advice on material movement to ensure that part production is kept both simple and smooth. This is when the wealth of experience and know-how amassed by TRUMPF’s experts comes to the foreground. For the customer, this means yet another step towards efficient manufacturing – and another check on the application consultant’s checklist.


This is what it looks like in practice:

Peter Huber Kältemaschinenbau GmbH, Offenburg

Everything is running smoothly again at Huber Kältemaschinenbau now that their programs have been fine tuned.

The task:

What is the right way to use TruTops to program our TruMatic 3000 combination machine for applications with different forming tools?


Programming was the focal point of our one-day application consultation. We operate TruTops Punch and wanted to continue using this model. We were experiencing some problems when using different forming tools for manufacturing because we were never quite sure how to program the machine to obtain the desired results. TRUMPF’s consultant was able to help our three programmers and machine operators on site, using concrete program examples. He also showed us which tools were best for specific forming operations, how we were to set them up, and how to program them in TruTops.

The results:

Our application consulting session greatly improved our ability to fine tune our programming. In many cases TRUMPF’s consultant used menu commands entirely different from the ones we were used to. We benefited from the fact that advice was given right alongside the machine. This let us test everything on the spot and later implement changes ourselves. This was a great help – everything is ship-shape again.


Erich Deinzer Stahl- und Metallverarbeitung GmbH, Nuremberg

Michael Pfeffer and Markus List learned tube processing tips and tricks from TRUMPF’s consultant.

The task:

How can we process tubes optimally and efficiently using our new TruLaser 3030 with RotoLas?


We had previously worked with RotoLas, but the new model features additional functions and how you operate it has changed a little, too. Our TRUMPF consultant was a specialist in tube processing and he spent two days giving our operators and programmers valuable tips – and showing us new options, too. The focal point in all of this was the actual operation of the machine. We went through all of the sequences and questions right at the controls, simulated those sequences with the help of test programs, and were soon able to correct many errors ourselves.

The results:

The outcome of application consulting is that we are now able to better utilize all of the potential built into our new TruLaser 3030 with RotoLas. The consulting process turned out to be a superb complement to the basic training courses. TRUMPF’s expert provided focused and detailed answers to all of our questions. He demonstrated solutions for specific applications. This has enabled us to refine and improve our tube processing operations. Of course, the most helpful aspect was having a tube processing specialist right here on our premises.


PreTec Schneidtechnologien GmbH, Dresden

At Pretec, operators and programmers now jointly ensure perfect work processes.

The task:

How can we best utilize the functions and manufacturing processes available with our new TruMatic 7000?


Two of TRUMPF’s specialists spent a whole week with our three programmers and operators. Training on the machine’s use was both individual and in a group. We felt this was especially important because there are many ways to program a part, and the programmers also have to know what is going on inside the machine – in order to achieve quick throughput. Above all, the interaction between automated components has to be right. This is not always an easy task. How do you determine when tools have to be changed? How does the sheet metal react after being subjected to many forming operations? In the quest for the best possible solution, attention was focused on part arrangement, step sequencing, and tool implementation. With their practical tips, TRUMPF’s specialists showed us how to manufacture certain shapes by punching, how to best nest the parts, and how to correctly secure sheets in the clamps. Thread tapping and special forming operations were new to us as well.

The results:

We were able to refine and improve the continuity of our work process, refining and improving part removal actions in particular. We now make the best possible use of the flap, the chute and the SortMaster. As a result of the consultation at the machine, we now work more confidently and efficiently when using punching tools, as well. For us, the results are optimization of quick tool changeover – combined with perfect part quality.


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Well advised

The TRUMPF application consultants deploy their expert knowledge at the point where it will later be used: directly at the machine in the customer’s production. With practical tips and a huge amount of know-how, they provide individual solutions to assist in improving productivity and product quality.

The range of consultancy services includes:

  • Improving the quality of parts and assemblies
  • Identifying and optimizing technology parameters
  • Use of appropriate tools for a variety of applications
  • Optimizing sheet layout
  • Increasing cutting speed
  • Reducing parts run time by utilizing special tools
  • Making use of all the resources of TruTops programming software