Page 17 - MetalForming August 2016

RealWheels new fiber-laser cutting machine fabricates a grille cover for the Black- hawks Camaro. RealWheels now uses the new machine for 85 percent of its products.
‘Mindfreak’ H2 Hummer and the famous collection of Chicago Blackhawks Chevro- let Camaros (as seen on this issue’s cover).
Fiber Takes Over for
Older CO2 Laser Technology
To do the work, RealWheels had been using a Mazak CO2 laser-cutting machine, but by 2015 management decided it need- ed a faster and more efficient solution. At first the company considered a new CO2 machine, but fiber-laser technology soon caught its eye.
Decision makers at RealWheels found that fiber-laser machines offered a wider range of cutting capabilities and higher cutting speeds than their CO2 counterparts, while using less consumables. In narrowing the focus to fiber laser machines, the com- pany had strict requirements for selecting
and so did the company. Today RealWheels operates in a 40,000-sq.-ft. facility in Gurnee, IL, with a team of 60 employ- ees that includes the Polka’s two sons, Cory, plant manager, and Greg, general manager and salesman.
New Department Opens Up New Work
Contract manufacturing also plays a key role in the success of the company, and the growth of that segment has spurred RealWheels to innovate.
“We realized this was a unique opportunity to add value for our customers,” says Greg Polka.
To capitalize on the opportunity, RealWheels introduced its Innovative Design Engineering Applications (IDEA) divi- sion in 2010, which led to a boost in projects from current customers and opened the door with new ones. IDEA handles custom grilles, fenderettes and specialty components, and also is responsible for projects such as Criss Angel’s custom
a system. For instance, RealWheels was interested in having automated features to quicken setup.
“We were looking for automatic nozzle changing and automatic focus to give a quick transition when switching materials,” Cory Polka explains.
And, though 3 kW was the only power option on some systems, RealWheels preferred 4 kW to enable processing of thicker materials for its IDEA division. An advanced cutting head would also be needed to process various mate- rial gauges. Another requirement was a ball transfer.
“We work with a lot of stainless steel and without a ball transfer the material can easily become damaged,” says Jan Polk. “Our customers will notice even the slightest scratches.”
Checking off its list of requirements, RealWheels selected the Optiplex Nexus 3015 fiber laser-cutting machine from Mazak Optonics Corp., Elgin, IL. The machine, installed this past March, offers a side door for simple internal access,
RealWheels uses its new laser cutter for 85 percent of its products, including Freightliner grilles (left) and Kenworth billet pedals (right).
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