Herkules Changes the Machine Tooling Game,
Slashing Costs With Additive Manufacturing

The primary challenge for Herkules was the production of specialized components for these remarkable machines, such as steady rests and soft loaders. A steady rest, for instance, is a critical support that braces a spinning metal roll — which can be several meters long and weigh several tons — ensuring it’s machined with micron-level precision.  

The initial approach involved milling the steady rests, which were previously made of metallic materials. This subtractive method proved to be fundamentally flawed. As Thomas Meyer, Head of Production at Herkules, explains, “Using conventional milling, our steady rests required excessive reworking, which called into question the profitability of the process.” For customers, this meant delivery times of eight to twelve weeks, and the installation itself was a tedious process. In the case of steady rest pads, it was taking up to 45 minutes per set and requiring a crane.  

The process was ultimately deemed unsuccessful and had to be abandoned, leaving a critical production need unmet. Herkules required a solution that could not only create complex geometries with industrial grade durability but also ensure consistent quality and tolerances. The company needed a manufacturing process that was as innovative and reliable as the machines they are known for. 

Solution

Herkules took a strategic leap forward by adopting an EOSINT P 760 system to bring AM in-house. A thorough profitability analysis backed the decision, projecting that the investment would be amortized in just 2.5 years. The material of choice was PA 2200, a durable and versatile polymer known for its strength and rigidity.  

Recognizing that technology is only as good as the people who use it, the company invested in comprehensive employee training and forged close partnerships with specialized suppliers. This created a center of excellence within their facility, running the EOS system across three shifts for maximum utilization.  

This new in-house capability provided the flexibility to move from concept to final part with unprecedented speed, enabling the production of innovative components that would be challenging, if not impossible, to create using traditional methods. The success of this initiative has been so profound that the company is already considering expanding upon its initial workflows, exploring processes like EHLA for even more efficient metal components in the future.

Results

The integration of EOS AM has delivered transformative technical and financial results. Herkules has achieved remarkable annual savings of several thousand € per machine, validating their initial profitability analysis. Furthermore, parts like the new additively manufactured steady rest pads can be changed up to 70 % faster, eliminating the need for a crane and thus streamlining maintenance workflows.  

The true testament to the project’s success, however, lies in the parts’ performance. PA 2200 components easily withstand the high loads exerted by the massive, multi-ton metal rolls they support. This real-world application powerfully illustrates the industrial-grade durability of additively manufactured polymers. 

Beyond the cost benefits, the biggest advantage has been the newfound design freedom. As Dr. Birk Brockmann, Chief Innovation Officer, noted, "The use of additive manufacturing processes using the EOS technology has had a transformative impact in savings and the ability to plan and manufacture more flexibly. In addition to enormous annual cost savings, the ability to rapidly iterate on prototypes and produce robust end-use parts has made us more agile. We have turned a manufacturing challenge into a strategic advantage and once again paid tribute to our commitment to innovation.”  

This agility is a direct result of drastically shortened development cycles, as functional prototypes can be produced in a fraction of the time. Furthermore, the ability to use decentralized manufacturing by producing parts directly on-site has minimized scrap and material waste, shortened delivery times, and given Herkules complete control over the production of robust components suitable for both functional prototypes and end-use applications. 

• Achieved annual cost savings of several thousand € per machine 
• Reduced part delivery times from up to 12 weeks to just 3 weeks 
• Accelerated part changeover by up to 70 %, eliminating the need for a crane 
• Gained design freedom to produce complex geometries impossible with traditional methods 
• Significantly shortened development cycles with rapid production of functional prototypes
• Increased manufacturing flexibility and reduced delivery times with on-demand, in-house production 
• Minimized scrap and material waste compared to subtractive manufacturing
• Enabled production of robust, durable components for both prototypes and end-use applications

As innovation leaders in the field of large machine tools, the companies of the HerkulesGroup stand for absolute reliability. The high level of vertical integration - all core components are manufactured within the Group - is just as much a hallmark of the Group as the global sales and service network with its own branches in all main markets. Since 1911, Herkules has been the world-leading specialist for roll machining. Herkules roll grinders and lathes are used where high-performance machine tools are required to ensure highly efficient machining of workpieces. In order to offer its customers single-source solutions, Herkules designs, builds, and delivers all the necessary equipment for roll machining. This includes roll shops and comprehensive equipment, as well as automation. Find out more: https://www.herkules-machinetools.com/