WEINIG MACHINERY FAQs: Counter profiles & your Powermat

PWT
Jan 20
2 min read

Sometimes, a standard flat pressure pad after a top horizontal head cannot securely hold a profile against the fence due to its shape, which leads to compromised quality

The solution is a counter profile shoe to hold it in position; however, producing a counter profile can be a lengthy and costly process, often avoided when possible.

Q: When should a counter profile be used?

A: There are two common scenarios for this:

When the profile’s shape makes it unstable as it feeds through the moulder
When producing profiles in multiples – counter profiles help control the split profiles, reducing movement during the splitting process.

Q: How are counter profiles traditionally made?

A: Traditionally, the process involves:

Creating a mirrored template of the profile to be produced.
Grinding a pair of cutters to match this profile.
Running a few lengths of hardwood through the moulder.
Cutting the hardwood to the required length for the counter profile.
Attaching it to the steel counter profile pad on the moulder.

The overall process is time-consuming and costly in terms of material and lost production time.

Q: How can this process be made faster & more efficient?

A: Weinig UK has developed a more cost-effective solution – 3D-printed counter profiles. After extensive testing, the company now offers tough, accurate and easy-to-use 3D-printed counter profiles, fully prepared for attachment to the pressure element on a Powermat moulder. Simply email a CAD drawing of the profile, and Weinig UK will handle the rest for a fixed cost. They’ve invested in CAD software, a post-processor and 3D printer, so why not give it a try?

Q: Will using a counter profile improve quality?

A: Yes. Counter profiles prevent profiles from shifting inside the machine, ensuring greater accuracy and consistency.

Q: Does a counter profile always mirror the profile BEING produced?

A: Not necessarily. Completely mirroring the profile increases friction, making it harder for the feed system to function efficiently. Instead, the goal is to apply sufficient pressure at key points to hold the profile in position while minimising resistance. A good example is when producing dowels in multiples, where the counter profile supports without excessive friction.

Q: What material is the 3D-printed counter profile made from?

A: Weinig UK uses carbon-reinforced nylon, which combines the strength of carbon fibre additives with the toughness and durability of nylon. This minimises friction, making it the most suitable 3D printing material for this application.

Q: How long is it expected to last?

A: Assuming no mechanical damage, the counter profile should last for thousands of metres while maintaining accuracy. If a replacement is needed, simply print another one! Just be careful when handling it as threaded inserts are included in the polymer, so avoid overtightening.

The Weinig Counter Profile Service

To order a 3D-printed counter profile, email sales.uk@weinig.com, including: