AFES 3DxT

AIM uses the world’s preeminent servo system.  Accuracy and repeatability of AIM machines are exceptional, so the wireforms produced will only be limited by the quality and consistency of the wire supplied.

S-curve positioning profiles give smoother acceleration and deceleration, minimizing shape distortion while achieving higher speeds at minimum possible power usage. Furthermore, the exclusive AIM Ultra option can in most cases double or triple the production rates from the standard models and grants the AIM equipment the title of the highest working speeds in the market.

AIM “Four Wheel Drive” wire feeders are capable of operating at lower pressure, which means no wire marking. Using V-groove rollers, you can run more than one wire diameter per groove and by using two V-grooves per roller, wire capacity doubles.  Power transmission is through a high torque, precision drive belts and in some cases, high precision planetary gearboxes; NO adjustments needed.

AccuForm machines come with “true wide-range straighteners”. A two-plane straightener with V-groove double row ball bearing rollers is standard on all AIM single head machines. Each plane contains two different roller sizes on two different center distances from each other.  For the lower half of the machine wire range, you would typically use only the smaller rollers and for the top half of the wire range only the larger rollers are used. This design allows easy and efficient adjustments and eliminates many difficulties one could have for the lower or upper end of the wire range. It is like having two wire straighteners incorporated into one assembly.

A quick release adjustor bar on each straightener minimizes changeover time. By using these preset adjustor straightener bars, changeover time can be as short as ten minutes allowing for a quick and easy wire diameter change. Wire diameter change is even faster with the AIM optional Automated Indexing Turret System (AITS), which can hold and index up to six straighteners.

Servo cutter for strong and fast cuts: A powerful servo cut mechanism provides fast and precise motion for the extra heavy duties of the machines, such as the cutting of the wire.

AIM machines incorporate simple design and easy access plus worldwide available parts.  Simplicity, robustness, functionality and speed are AIM’s basic engineering principals. Easy tool changeover makes the setup quick and efficient. AIM machines have an excellent reputation for customer support and spare parts delivery.

AIM uses robust engineering for long life and low maintenance. Using enclosed type brushless servomotors along with highest precision planetary gearboxes provides the best machine operation. All critical components have over-temperature, over-current, and over-voltage protection installed.  All bearings used are oversized and double-sealed for longer life expectancy and lower maintenance.  The design of the AccuForm machines provides for maximum safety standards and life expectancy factors. AFES machines are carrying a one year parts and labor limited warranty, optionally extendable. Excluded are the wear parts that ¡°touch¡± the wire (such us cutters, rollers, etc.), although all of these wear parts are made from the hardest tool steels and heat-treated to Rockwell scale 55°-65° degrees.

For the AFM line, the newest Windows® is standard. No extra fees, no contract needed!

The Software Animation utility allows the user to view an animated production simulation of a part before the machine even produces it! This way the user can easily verify the programs for mistakes and errors. A collision detection feature is available, so that the user can prevent program miscalculations and rearrange part flow for optimum production.

Another AIM pioneering feature: “Dial-A-Service™” allows access to any AIM machine worldwide. The customer simply connects the machine to a telephone line or an Internet gateway and the machine’s computer connects to AIM’s Technical Support department.  Within minutes, diagnostics can be reviewed and initiated.

SmartEditor® has a standard DXF/XYZ import feature that can import your CAD files directly and convert them into part files on your screen. AIM also provides the original machine buyer Lifetime Free Upgrades on the machine software. Since AIM compiles its own software, all suggestions and program change requests are fulfilled regularly and free of charge, taken that the requested change or improvement is beneficial for the majority of the users and falls within AIM’s expertise.

Statistical analysis with the touch of a button – a standard SmartEditor® feature! Let the computer figure it out – production rates, time, shifts, days, wire needed, wire spools required, including spool changeover time. All the factors involved are parametric and are customizable to fit every need.  Using the SmartEditor® Office version (available upon customer request), you can use the “EZ-Quote” analysis from your office PC.  Production statistics can be saved automatically, locally on the machine or on a network computer for review and analysis frequently needed by ISO 9000 quality analysis programs or the customer’s lean manufacturing system.

AFES-3Dx-T Machine Description

At AIM, we don’t just build machines—we engineer solutions that redefine what’s possible on your production floor. The AFES-3DxTd, part of our AccuForm® line, is the ultimate wire bending system for manufacturers demanding unmatched speed, power, and versatility—all in a single, highly efficient work cell or standalone unit.

Standalone Power – End-to-End Automation

The standalone AFES-3DxTd automates the entire process: feeding wire from coil, straightening, bending, and cutting—with virtually zero waste. Thanks to a push-feed system and a cutter positioned directly adjacent to the tooling, the machine seamlessly ejects finished parts while the next one is already forming. It doesn’t get faster—or more efficient—than that.

Modular Cell Integration – One Bender, Unlimited Possibilities

Highly adaptable on its own, the AFES-3DxTd can be expanded into a complete modular production cell. Equipped with Turret Tools for automatic tool changes, it becomes the central hub for fully integrated automation.

When paired with AIM’s optional accessories—like chamfering units, threading heads, hydraulic presses, welders, or conveyors—the system becomes a powerful, compact, and labor-saving cell. All accessories sit within the safety enclosure for a space-saving, production-boosting solution.

Note: Full cell integration may require robotic handling and customization, quoted based on your unique production needs. Pre-wired options are available for future upgrades. Contact an AIM Technical Sales Executive to explore your options.

Turret Tools – Fast, Flexible, and Built for Change

AIM’s patented Turret Tools system enables automatic, servo-driven tool changes mid-cycle—switching between up to one of eight bend radii in under one second. Included in every system:

• Roller pin for sweeping radii
• Hard pin for sharp angle bends
• Cluster tool with up to 8 bend radii
• “Shear” Cutters, for clean bur-free cuts at “lightning fast” speed thanks to the integral servo cutter design.

Tool kits can be swapped in under five minutes, enabling fast transitions between part runs in high-mix, high-volume environments with differing wire sizes and part geometries.

Longest 3D Bender Arm in Its Class – Sets a new standard.

For large frames, paint hooks, and other extremely long parts requiring bending back towards the bender, the AFES-3DxTd offers the longest bend-back clearance in its category—approximately 35 inches on the smallest 8mm model and only greater on larger models. Add the optional removable support table for even greater flexibility, allowing you to form large, complex parts without having worrying about the part sagging and deforming due to gravity.

SmartEditor® – Program with Simplicity

AIM’s exclusive SmartEditor® software transforms how parts are programmed. Operators enter just lengths and angles—the system does the rest, automatically calculating motion paths, tool changes, and sequences. For advanced users, full manual control is always available.

What once took dozens of steps now takes just a few.

Notes:

• Optional Step File Importation Feature Available, it will program a part for the user allowing the operator more time to optimize the program or run as is after import.
• New parts can be programmed while the machine is running production of another, utilizing the included 3D machine simulation feature.

Unmatched Value – Performance Per Dollar

The AFES-3DxTd offers more production power and flexibility per dollar than any other machine in its class. From its robust frame incorporating solid steel plates, to smart software, and tool integration, it’s built to deliver high performance at an exceptional value—for operations of any size.

Customizable Add-Ons – Scale with Confidence

Expand your AFES-3DxTd with AIM’s full suite of optional accessories:

• Chamfering Units (CHE6, CHE14)
• Hydraulic Press Module (AP40)
• Accu-Threader™ ATH-x Series with Three Tool high-speed tool changer
• Butt Welding Unit (BW40i) – DC welder for the strongest, cleanest welds
• Automated part handling – pick/transfer units, accumulators, and conveyors

With over 200+ possible configurations, AIM will help design a cell tailored to your production volume, part complexity, and floor space.

Engineered to Run. Built to Last.

Constructed robustly, incorporating solid steel plates, the AFES-3DxTd minimizes vibration and maximizes structural integrity—delivering high-speed performance and repeatable accuracy shift after shift without compromise.

Pound for Pound, the Best Value in the Industry

When it comes to cost-to-capability, nothing compares to the AFES line. Designed for maximum flexibility and feature density, the AFES-3DxTd delivers more functionality and production power per dollar than any other wire bending machine on the market.

From its structural strength enabling continuous high speed production, to its smart software and versatile tool integration, this machine is pound for pound the best value in the industry—making it the smartest investment for operations of any scale.

Go to Contact Sales – AIM Machines and/or call +1.813-818-8222 and ask for a Technical Sales Executive to help you find the right machine solution for your needs today!

Additional Features:

• Robust frame construction for fast and consistent production
• SmartEditor® Windows® programming, office version available for off-line programming
• Dual processors allow concurrent part production and new part programming
• Instant Production Statistics for estimating
• “Dial-A-Service” tech support via modem or Internet
• Optional extra I/O for auxiliary equipment
• Optional STEP File Import
• Tool changeover in 8 minutes. Highest overall forming speeds in the industry
• CAD import of DXF/XYZ files directly into SmartEditor® programming software

AFES-3Dx-T Machine Details

1.1 Two Plane Wire Straightener
Every AFES-3Dx machine is equipped with a two-plane wire straightener. Each plane consists of 11 “V” groove roller bearings. Two different diameters of rollers allow straightening a wider range of wire with just one straightener. Wire range: 2mm to 8mm (0.07” to 0.315”). Wire linearity: < 5:1000 at 6mm (0.236”) wire diameter. For wire diameters under 2mm (0.07”), an additional straightener is required.

1.2 Feeder
Used for the feeding and positioning of the wire. Consists of four driven rollers, one wire guide, sprocket-belt reduction unit, precision hi-torque drive (HTD) belts and one brushless servomotor.

Feed Speed: 152 meters/min (506 ft/min)
Repeatability: +0.1 mm (+0.004″)

1.3 Wire Length Measuring Device
Wire positioning feedback consists of a pair of rollers: one stationary and one with an adjustable pneumatic load. The stationary roller connects through a flexible coupler directly to an incremental rotary encoder providing accurate position feedback to the machine controller.

1.4 Machine Controller & Operator Panel Computer: Industrial Panel PC, integrated touch screen, 15” LCD color monitor, industrial sealed keyboard with integrated pointing device, high capacity storage hard drive (80 GB min), Fast Ethernet network ready and video camera for machine monitoring, videoconferencing or servicing available. The operating system is Windows® 10.

1.5 Z-Axis Arm:Bender mounts on an H-Beam base that rotates around the center of the wire. All electrical connections pass through a robust energy chain with a smart design that allows +/-190 degrees of motion.

1.6 Servo Cutter Unit
Strong Servo and Gearbox combination for fast cutting and long life.

1.7 Bending Head and 1.8 Cutting unit: Standard turret tooling consists of a cluster with four bending radii and both hard and roller bending pins.

Max. Bending angle Unlimited
Precision +0.05º
Drive AC brushless servo motor
Transmission Precision planetary gearbox
Cutter material D2 tool steel, hardened 58 HRC

Wire Payoff unit (Turntable): Model P270-5, fully automatic powered Payoff Unit, capable of handling coils weighing up to 2000 Kg (4400 Lbs), 5 Hp AC motor, electronic speed control with AC Vector Drive, adjustable tension for the dancer control arm. Speed range: 5-70 RPM, rotating base Ø: 1140mm (45″), heavy-duty construction with oversized tapered bearings assures maintenance-free operation, main electrical panel supplies all electrics – eliminating the need for a separate electrical connection box.

Utility Requirements:

480 VAC, 3 Phase 50/60 Hz, < 1 CFM air supply.

400VAC, 3 Phase & CE Certification available

• Concurrent Operations: Dual processor allows programming a part while running production
• Production Statistics for cost estimating & scheduling
• 2D DXF file transfer & optional 3D Step file import
• Animation / Bending simulation allows you to see programmed moves before running production
• Remote, off-line programming with stand-alone software or through installed network card
• Color touch screen monitor and industrial grade sealed keyboard for data entry
• Simple programming with Windows 10 based operating system
• Exceptional accuracy and repeatability
• Sealed, oversize bearings for low maintenance operation
• Wire fed directly from coil
• A variety of servo drive options for combinations of faster feed and bending speeds
• One keystroke transition between Metric and English units of measure
• Merge individual part programs for production of complete assemblies or program to make alternating parts
• Programmable delay or hold functions to match downstream operations in work cells
• Spiral software function allows user to define any spiral with just three numbers
• Easily accessible tooling for minimal setup and change over time
• Hardened and precision ground tool steel moving parts for exceptional wear and tool life
• Optional I/O’s for interconnection of auxiliary equipment such as robotics, threading units & inspection devices
• Highest overall production speeds in the industry
• Network ready for “Dial-A-Service”
• Serial, Ethernet & USB Ports
• Safety barrier with safety interlock door included
• Extended rotation of bending arm for efficiency and reliability
• Fully automated payoff unit included: 5Hp, 2000 Kgr (4500 Lbs) capacity
• Temperature controlled electronics cabinets with washable filters