Onsrud HSD Series
Key Specifications
X-Axis Travel
Y-Axis Travel
Z-Axis Travel
Spindle Speed
Spindle Power
Feed Rate (Max)
Overview
The Onsrud HSD Series is a family of high-speed CNC routing systems purpose-built for machining honeycomb-core composite panels, foam core assemblies, and lightweight structural sandwich structures used extensively in aerospace and defense interiors. Engineered in Illinois with Onsrud's decades of composites expertise, the HSD platform delivers the combination of controlled cutting depth, vacuum fixturing precision, and high-spindle RPM needed to produce clean, delamination-free edges in Nomex honeycomb, aluminum honeycomb, and foam-core carbon fiber laminates.
At the heart of the HSD Series is a high-frequency electro-spindle delivering up to 24,000 RPM with selectable torque curves to suit both thin-skin CFRP facesheets and thick foam core removal passes. The gantry structure is fabricated from welded steel with precision-ground linear guideways, offering the rigidity to maintain cut quality across large panel formats without the resonance issues that plague lighter-duty router platforms. Integrated vacuum zone control allows operators to isolate specific table regions, accommodating panels ranging from small door liners to full overhead bin assemblies.
The HSD Series supports a broad range of routing, trimming, drilling, and countersinking operations in a single setup, which is critical for aerospace interior suppliers managing tight tolerance stacks. Onsrud's proprietary pod-and-rail clamping system can be swapped for vacuum tooling to handle parts with complex planforms or cutouts. Optional dust collection manifolds and mist-suppression systems address the particulate and health hazards associated with cutting dry carbon fiber and aramid materials.
Typical applications include aircraft interior panels (sidewalls, ceiling panels, overhead bins), marine composite decking, automotive CFRP door inners, and wind turbine nacelle covers. The HSD Series integrates with major CAM packages including Mastercam, Siemens NX, and Catia-based toolpath outputs, and is supported by Onsrud's North American service network with rapid spindle exchange programs to minimize production downtime.
Full Specifications
| Parameter | Value |
|---|---|
| X-Axis Travel | Up to 3,048 mm (120 in) |
| Y-Axis Travel | Up to 1,524 mm (60 in) |
| Z-Axis Travel | 305 mm (12 in) |
| Spindle Speed | Up to 24,000 RPM |
| Spindle Power | 7.5 kW (10 hp) |
| Feed Rate (Max) | 30,000 mm/min (1,181 ipm) |
| Table Type | T-slot + vacuum zone grid |
| Vacuum Zones | Up to 12 independently controlled zones |
| Control | Siemens 828D or Fagor 8065 |
| Tool Capacity (ATC) | 8-position carousel |
| Manufacturer | Laguna |
| Model | SmartShop |
Specifications sourced from machinio.com — verified 2026-03-28
Strengths & Limitations
Strengths
- High-frequency spindle optimized for aramid and honeycomb composite cutting with minimal delamination
- Multi-zone vacuum table handles irregular panel shapes and cutout-heavy parts without edge clamps
- Rigid welded steel gantry maintains accuracy across large panel formats at high feed rates
- Integrated dust collection manifold keeps fiber particulate contained at the source
- Onsrud's established North American service network with rapid spindle swap program reduces downtime
Limitations
- Z-axis stroke is relatively short, limiting use on thick stacked or contoured composite assemblies
- Eight-position ATC is modest for complex parts requiring many specialty composite tooling grades
- Premium pricing compared to general-purpose 3-axis routers may be difficult to justify for low-volume shops
Best For
Frequently Asked Questions
01
The HSD Series is optimized for Nomex honeycomb, aluminum honeycomb, foam core CFRP and GFRP sandwich panels, solid CFRP laminates, and aramid (Kevlar) fabrics. The high-speed spindle combined with Onsrud's recommended tooling geometries keeps cutting forces low enough to prevent facesheet peeling and core crush.
02
The table surface features a grid of vacuum ports divided into up to 12 independently controlled zones. Operators activate only the zones under the workpiece footprint, which maximizes hold-down force on the part while preventing vacuum loss through open areas. Zone mapping is programmable from the control for repeat setups.
03
Yes. With the automatic tool changer, the HSD can switch between routing bits, drill bits, countersink tools, and specialty compression-cut tools within a single program. This allows trim, drill, and countersink operations on composite panels to be completed in one setup, reducing handling and datum shifts.
04
The HSD accepts standard G-code post-processors from Mastercam, Siemens NX, SolidWorks CAM, Catia V5/V6, and most major CAM platforms. Onsrud provides validated post-processor configurations for common CAM packages upon purchase.
05
Lead times vary by configuration but are typically 16–24 weeks from order to delivery. Onsrud's installation team handles machine commissioning, vacuum system verification, and initial operator training on-site, typically requiring 2–3 days.
Videos
C.R. Onsrud, Inc.
C.R. Onsrud, Inc.
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C.R. Onsrud, Inc.
C.R. Onsrud, Inc.
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