But appearances can be deceiving. Behind the traditional housing lies a piece of the future – a machine that was once operated entirely manually and is now digitally networked and performs tasks with the help of AI, almost without any human programming.

What is demonstrated here is an example of how long-serving production facilities can be transformed into efficient, autonomous, and sustainable factory systems through targeted modernization.

Many industrial machines in Germany are decades old and yet still technically robust. They date back to a time when neither CAD data nor digital controls existed. The milling machine from Kaiserslautern also belongs to this generation. Originally, a technician had to program each step manually – a laborious, error-prone and time-consuming process.

Today, it is equipped with new motors, sensors, and software-based controls. What used to be laboriously controlled by cranks is now handled by a digital twin that knows exactly how the machine needs to move and what forces are at work.

“We wanted to show that even a machine that is decades old can still be given a digital life,” says Patrick Kremser, a researcher at WSKL who played a key role in the development.

Digital twin – the invisible revolution

The digital twin, a completely virtual replica of the machine, is at the heart of the modernization. It not only simulates movements and loads, but also automatically executes production orders.

What used to take days can now be done in minutes: in the CAD program, all you have to do is change a pocket or a hole. The software immediately translates this change into the appropriate milling strategy.

Before the real machine starts, the system simulates each step with millimeter precision. This allows early detection of whether tools could collide, how much energy an order will consume, or how long the machining will take.

Kremser describes the advantage as follows: “We first make it digitally visible whether an idea works – and only then does the machine actually mill. This saves an enormous amount of time, money, and material.”

Retrofit instead of new construction

A new CNC machining center can easily cost tens of thousands of euros and is depreciated over decades. Many companies are reluctant to make such investments – especially if the existing machines are still running reliably.

This is exactly where WSKL comes in. Targeted retrofitting can make even 60- or 70-year-old special-purpose machines competitive again. There is great interest from industry: numerous special-purpose machine manufacturers have already inquired, as many older systems are no longer manufactured or simply no longer work.

“Modernization is worthwhile – and often it is the only realistic option,” says Kremser. “You don't have to buy a whole new factory to remain competitive. Often, it is enough to digitally upgrade existing machines. We provide support in this process.”