Cybaman Replicator

Rapid Functional Metal Parts

The Cybaman Replicator is a fully automatic computer controlled rapid manufacturing system which employs both subtractive or additive processes to produce a component.


Developed specifically for high speed machining of 3D metal components, it presents each facet of a workpiece, to the cutting tool in an automatic sequence. Toolpaths are generated using hyperMill CAD/CAM software and then converted into machine movement with the cybaman postprocessor.


The cybaman laser machine can be supplied with a laser powder desposition head for rapidly building metal parts directly from a CAD model.

Multiple CAD Formats

Accepts all current data exchange formats dxf, dwg, iges, sat, vda, STEP, STL.

Reverse Engineering

Using the optional scanning system, parts can be imported into the CAD for subsequent replication with the cybaman system.

Cybaman Replicator


  • Compact footprint
  • Low power consumption
  • High accuracy and repeatability
  • Lights out operation
  • Large work envelope
  • Quiet operation
  • 6 axis machining capability
  • Remote monitoring & control


  • Rapid Functional Parts
  • Full 3D in One Hit
  • Small Footprint : Part Size
  • Eliminates Fixtures
  • CAD to Part in minutes
  • Precision Parts


  • Aerospace Alloys
  • Aluminium
  • Titanium
  • Zirconium oxide
  • Cobalt Chrome
  • Ceramics
  • Precious metals
  • PMMA


The Workstation houses a 6 Axes PC Based - CNC Software driven Cybaman Positioning System comprising 3 axes Articulated Robotic Manipulator and a Hi- Speed Machining Spindle mounted on 3 Linear Axes.

Cybaman Replicator
Control System PC Based, 6 Axes Closed Loop Servo
Linear Axes Travel X - 200mm Y - 300mm Z - 200mm
Rotary Axes Chuck A - 360 0 continuous, B - +/- 180 0 C - +/- 180 0
Machine frame Epoxy Resin Rose and Black Granite in natural colour
Machine Frame Envelope 800mm x 760mm x 760 mm high - sealed enclosure- interlocked door
Weight 200 Kg
Component Envelope 170 mm x 170 mm x 170 mm
Maximum cutting feed rate 12m/min
Leadscrew type c6 Precision Ground Ball-crew
Servomotors Brushless DC Servo
Accuracy +/- 12 µ
Resolutions Linear   +/- 1µ    Rotary    1 arc sec
Repeatability Linear    +/- 2µ
3D Reference datum point accuracy +/- 6µ varies as bearing specification
Max table load 6kg
Spindle Speed & type 50,000 rpm –H.S. Hi-Freq., water cooled with pneumatic drawbar
ATC option 5 ATC HSK E25 tooling
Spindle power 2.2 kw
Coolant "Unilube” Mineral Oil Lubricating and Coolant Mist System
Compressed Air Supply On board miniature “quiet running” 75 litres/min air compressor 8 litre receiver

3 Axes CNC - Cybaman Manipulator

Cyba and ENGIN-X: stress measurement for the 21st century!

Cybaman Manipulator The ISIS Facility, Rutherford Appleton Laboratory, UK, is a world-leading source of neutrons for scientific research. By studying how beams of these particles are scattered from materials, researchers gain information which in general terms tells them about “where atoms are and what they do”.

One important area of application is in the measurement of residual stresses in engineering components. This technique is of considerable importance in safety-critical industries such as the aerospace and automotive sectors.

The ENGIN-X beamline at ISIS is a purpose-built instrument specifically dedicated to this technique. In order to measure the full stress state, it is necessary to measure strain in a number of sample directions, and therefore to rotate the sample into a number of orientations. The Cybaman Manipulator provides the ideal tool to automate the procedure for components of up to 25kg in weight, and facilitates easy switching back and forth between orientations. The Manipulator sits on an xyz translation table, enabling stresses to be mapped in 3D throughout a component. The orientation procedure is software-controlled: a computer model of the component (from CAD or laser-scanned point cloud data) is manipulated in the software to determine the correct measurement orientation, which is then fed to the Manipulator to execute the required rotations. For example, this procedure could be used to map strain perpendicular to a complex, curved surface, such as that of a fanblade.

For more details about the ENGIN-X instrument, visit

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Winner of the NPL Award for Manufacturing Excellence 2001.