Falcon CNC Swiss — March 27, 2026
Overview
The Mitsubishi Electric new edge digital twin technology is capable of rectifying CNC machine tool facility faults within the real-time interval thus resulting in approximately a 50% reduction of machining errors as well as errors associated with machinery faults. Partnered with RWTH Aachen University to develop, the system will combat deformation due to the effects of the cutting force applied against the moving part, as this deformation issue has continued to be a concern in the precision manufacturing industry for many years. Component purchasers will see the benefit of this system's inception, leading to improvements in consistent product quality along with lowered scrap rates in production.
What Happened
Mitsubishi Electric Corporation announced their new digital twin technology for CNC machine tool error compensation on March 25th, 2026. This technology uses Mitsubishi’s own compact physical model based on high sampling rate data such as axis positions, motor currents and cutting forces in order to estimate machining errors that occur during machine operation and feed the corrections back into the control loop in real-time.
The results from testing the digital twin technology on a CNC Machine Tool at RWTH Aachen University proved that the digital twin technology could reduce machining errors caused by workpiece deformation due to cutting tool forces by up to 50%. The joint research project conducted from April 2023 through March 2026 was focused on real-time, high-speed processing of data utilizing online edge computing.
Technology Breakdown
Traditional Process: Tool pressure can create a workpiece deflection in traditional CNC machining, in addition that the deflection can be greater when cutting thin walled or slinder parts. Errors are exacerbated as they add up from multiple inspect cycles until finally discovered, usually only after machining; therefore, scrap and re-machine are produced.
New Process: The Mitsubishi Electric system is a digital twin of the actual cutting process in real time. The minimum physical model made up of the fewest necessary equations and uses high frequency (axis position, current, and cutting force) data streams taken frequently enough to detect transient deflection events. The model is then able to provide in real time the deflection and forward corrections commands to the CNC control prior to the errors becoming imbedded in the workpiece.
Key Difference: Unlike the traditional “cut then measure” processes, this provides Closed Loop Corrections during the machining process while cutting. The system actually provides real time stabilization of the deflection of the workpiece during the machining process. For applications requiring tight tolerances down to ±0.0001”, this is a significant difference.
Effect on the manufacturing sector
For U.S. manufacturing: sector is under increased pressure to produce aerospace, medical, and defense parts with a defect-free rate due to the rise in reshoring. Technologies that are reducing variability will help fulfill this requirement. The ability to compensate for deflections during manufacturing will reduce the skill level required to manufacture parts with complex geometries and will expand the workforce that can be utilized for those types of parts.
For high-mix, low-volume production: Job shops producing medical implants or prototypes, where setup changes often, will benefit from a substantial reduction in setup tuning time to begin production. The consistent surface finish and dimensional stability produced through the use of real-time error compensation will require no additional steps for inspection after the manufacturing process has been completed.
Siemens / FANUC's announcements align with broader industry trends. At the recent RXD Conference hosted by Siemens, there was an emphasis on the use of artificial intelligence and the implementation of digital twins for use in machining processes. Similarly, FANUC's $90 million expansion of automation in the state of Michigan is indicative of the continual increase in the amount of automation used in U.S. manufacturing. The introduction of real-time error compensation represents a convergence of these forces (AI driven processes modeled directly to control).
Falcon Insight
As an engineer, achieving a 50% reduction in error is impressive; however, the key takeaway is the way in which these errors are reduced. Deflection error has an inherent non-linear characteristic; the errors grow quite large while doing the bulk of the machining effort (heavy rough cuts) and become smaller while the machining operation is nearing conclusion (finishing). Because of the nature of CNC (computer numerically controlled) programming, programmers apply lower speeds and feeds as a precaution against deflection errors. Unfortunately, this process adversely affects cycle times when aerospace, medical or precision-machined parts must be produced.
Using a digital twin approach will give an engineer the ability to perform what engineers refer to as 'adaptive feed control with a position compensator'. This solution provides a way to track and model deflection errors in real time, allowing the engineering team to:
Keep all aggressive roughing parameters in place without the fear of creating a distorted part
Make the transition to finishing with accurate geometry measurements
Remove or significantly reduce the number of spring passes required for producing thin wall features
For manufacturers that make Swiss-type lathes, and 5-axis mills, and are producing parts from hard materials (316 stainless steel, Titanium 6-4-4V and PEEK), the expected results are shorter cycle times and higher first pass yield. For us at Falcon CNC Swiss, tolerances of ± 0.0001” are standard use for the manufacture of parts for the medical or aerospace industries; therefore, these types of technologies that close the loop between cutting-force measurement and dimensional result are highly applicable to our precision CNC machining service.
What Buyers Need to Know
If you purchase precision machined parts (e.g., aerospace parts or medical implants), then you need to consider supplier selection criteria that have an impact due to this development.
Ask about error compensation capabilities. Suppliers investing in newer CNC controls (Mitsubishi, Siemens, Fanuc) may already have access to adaptive control features. Not all shops enable them.
Deflection-sensitive geometries require advanced control. Thin walls, long slender features, and interrupted cuts are where error compensation delivers the most value. If your parts have these characteristics, confirm your supplier’s approach to managing deflection.
Documentation and traceability matter. Closed-loop systems generate rich process data. For regulated industries, this supports validation and lot traceability requirements.
Consider suppliers with prior experience with multi-axis CNC milling and turning processes that have incorporated advanced control strategies into their operations when evaluating suppliers for complex, high tolerance projects. Refer to our CNC Machining Capabilities overview for additional information on how we approach these requirements.
Sources
FAQ
Q: Will this new technology free up skilled machinists from their jobs?
A: No, rather than having to do manual compensation during set up, machinists will now be able to optimise the digital model and interpret the results. Skilled operators are still very important in this process.
Q: Can I use this new technology with my existing CNC machine?
A: Currently it will require a Mitsubishi Electric CNC control system and the required edge computing hardware in order to operate with this technology. Retrofits to compatible systems may be possible, but currently there are no aftermarket solutions available.
Q: Which materials will benefit the most from this technology?
A: Materials with lower stiffness-to-strength ratios, such as aluminium or titanium, are likely to have a higher incidence of deflection under cutting loads and, therefore, are likely to be candidates for this new technology.
Q: How will this new technology improve lead times?
A: The ability to reduce scrap and lessen the need for rework will reduce lead times as compared to current processes, especially on complex parts that would otherwise require multiple set-up iterations.
