Key Capabilities
- Automated cutting and trimming of pressure vessel heads up to Ø 6 m (20+ ft) and beyond
- Weld preparation on vessel head segments (petals) for oversized vessels exceeding Ø 10 m (32+ ft)
- Straight (normal-to-surface) cutting and full V / A / Y / X / K weld preparation on any contour
- Full-surface 3D laser scanning and real-shape measurement of each vessel head using mScan
- Automatic cutting program generation from 3D models using mCAM
- Automatic adjustment of cutting paths to match the actual vessel head geometry
- Marking of synchronization and alignment lines for easier fit-up and assembly
- Weld seam detection to prevent cutting through existing welds
- Workpiece verification and generation of a Vessel Head Precision Protocol
Main Advantages for Fabricators
- Massive time savings compared to manual or template-based processes
- Exceptional contour positioning and cut-edge accuracy
- Reliable, repeatable bevel cutting with long-term precision
- Easy maintenance of the bevel head thanks to MicroStep’s patented ACTG® technology
- One machine, multiple applications: combine vessel head cutting with plate, pipe, and beam cutting on the same gantry (plasma, oxyfuel, or both)
Precision Powered by mScan
Enhance vessel head processing accuracy with mScan, MicroStep’s advanced 3D point cloud mapping solution. Utilize laser interferometer-measured kinematics and MicroStep´s ACTG® auto-calibration for optimal performance.
- Full-surface laser scanning of each vessel head
- Real-time integration of scan data with machine kinematics
- Automatic compensation for geometric deviations
Result: Accurate cutting and weld preparation – even on imperfect, out-of-round, or distorted vessel heads.
Easy-to-Use Software.
Industrial-Grade Results.
- Intuitive 3D CAM workflow
- Automated data flow from scan to cut
- Consistent results independent of operator skill
- One supplier for machine, control system, CAM, and scanning software
Any shape any orientation
The system processes all common pressure vessel head geometries, including:
Innovations in Sheet Metal and Dished End Cutting
Bosch Industriekessel GmbH, part of Bosch Thermotechnik GmbH, with over 120,000 installed boiler systems worldwide, selected MicroStep technology for metal cutting at its Gunzenhausen site. Since 2015, the company has been using two 3D plasma cutting machines, operating in two- and three-shift systems. One of the machines is an MG series with a double gantry, capable of processing both sheet metal and dished ends. The other, a CombiCut, is dedicated solely to sheet metal cutting. These machines handle steel thicknesses from 8 to 45 mm, producing unique and small-series parts. Bosch made the decision after extensive tests and development work to meet tight tolerances for hole and bevel cutting. The experience gained from a similar installation in Russia further solidified the choice of MicroStep, ensuring high precision and improved efficiency.
Automated Dished End Processing for Increased Quality and Efficiency
The new machines have been in continuous operation since their installation, providing significant benefits, particularly in dished end processing. Previously, dished ends were supplied semi-finished and required extensive manual finishing, a time-consuming process that made achieving the required precision challenging. With the new systems, holes and bevels are applied automatically, streamlining production and improving accuracy. This automation has eliminated manual interventions, reducing both time and the potential for errors. “It’s a great leap in quality, a whole new world,” says Christian Loschmidt, head of technical planning at Bosch. The combination of sheet metal and dished end cutting on one machine has greatly simplified workflows and allowed Bosch to meet high-quality standards while increasing production efficiency.
Proven Precision and Reliability in MicroStep Technology
The decision to choose MicroStep technology was based on the company’s previous positive experience with the brand and its ability to meet stringent precision requirements. Bosch’s plants in Russia had already used MicroStep’s MG series plasma cutting machine, which delivered excellent results. The machines at the Gunzenhausen site were selected after rigorous testing, with MicroStep adjusting their technology to meet Bosch’s precise specifications for hole and bevel cutting. These developments were essential for Bosch, which regularly requires complex cuts for special parts, including ignitions and unique geometries. With these new machines, Bosch now enjoys enhanced cutting speeds, high precision, and reduced production time, making MicroStep the ideal partner for their cutting needs.
