Zimmermann Expands 5-Axis Portal Milling Capacity

Large-format machining systems are increasingly being adapted for lightweight materials and composite manufacturing, particularly in aerospace, tooling, and industrial model production. In this context, Zimmermann Milling Solutions introduced the FZU22, a 5-axis portal milling machine designed for machining large structural components and molds from aluminum, plastics, wood, and carbon-fiber-reinforced composites. The machine will be exhibited at IMTS 2026, taking place from September 14-19, 2026, in Chicago.

Large-format machining for lightweight structures
The FZU22 extends Zimmermann’s portal milling portfolio with a machine configured for applications requiring high material versatility and precise contour machining. The system is designed to process both conventional substrates and composite materials used in aerospace and industrial manufacturing workflows, where lightweight structures and complex mold geometries are common.

An overhead gantry architecture supports machining stability during large-part processing while maintaining access to the work area. The machine integrates a specially developed 5-axis milling head equipped with a 15 kW spindle for machining complex contours, deep cavities, and narrow pockets in large molds and structural parts.

The standard configuration includes a 24-position automatic tool changer and either Siemens or Heidenhain CNC controls for motion control and process monitoring. The CNC integration supports continuous multi-axis machining operations commonly required in composite tooling and precision mold manufacturing.

Travel range and machine dynamics
The machine provides an X-axis travel range between 71 in and 98 in, Y-axis travel from 118 in to 138 in, and 49 in of Z-axis movement. Feed rates on the X and Y axes reach 2756 ipm, while acceleration values range from 118 in/s² to 197 in/s² depending on machine configuration.

Zimmermann specifies ISO 230-2 accuracy for the system, a standard commonly used to evaluate positioning precision in CNC machine tools. Despite the working envelope, the machine footprint measures approximately 11 ft by 15 ft, reducing floor-space requirements in production environments where large-format machining equipment often requires dedicated infrastructure.

The FZU22 also supports multiple milling head configurations, allowing adaptation for different machining processes and material requirements.

Optional systems for aerospace and composite processing
Optional equipment includes touch-probe measurement, tool measurement systems, enclosed work areas, chip conveyors, mist and dust extraction systems, minimum quantity lubrication, and vacuum systems. These additions support machining environments involving composite dust control, fine surface finishing, and automated tool verification.

The machine configuration scheduled for display at IMTS 2026 will additionally include an ultrasonic cutting system designed for aerospace insulation materials. Ultrasonic-assisted cutting systems are typically used to reduce cutting resistance and material deformation when processing soft composite insulation layers and multilayer aerospace materials.

Edited by Aishwarya Mambet, Induportals Editor, with AI assistance.

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