1.) Consultation, construction and simulation
Efficiency begins with good advice!
Materials and processes are introduced. We jointly select the best combination taking into account your specifications as regards the required material properties and quantity.
Together with you, we ensure the casting-compatible construction of your parts. 3D CAD construction ensures optimal planning options for each tool. Each casting is simulated by us before manufacture. This allows us to optimise the mould filling and can prevent defects in casting.
We plan the entire process chain comprising casting, fine blanking and other post-processing steps. To achieve this, we construct and manufacture permanent moulds, high pressure die casting moulds, deburring tools and machining devices. During the planning and construction phase carried out on modern 3D CAD systems, individual solutions are developed in close contact with the customer. For reasons of efficiency we recommend that our standards are referenced wherever possible.
2.) Mould Making and Toolmaking
Thanks to our networked systems connecting CAD to CAM and our HSC milling machines, we achieve great reliability and quality in manufacture and also speedy project execution.
Within the framework of the PDCA (Plan-Do-Check-Act), team-oriented solutions are implemented for existing inefficiencies.
3.) Foundry Technology
We have more than 5 horizontal and 3 vertical die casting machines with clamping forces of up to 400t. The optimal choice of die-casting machine is made based on your component.
Our die-casting machines are monitored in real time. Intervention limits are set for each order so as to increase the reliability of the process. As soon as the tolerance zone is left, production is halted. Each order is analysed and compared with other orders. The data collected in this manner allows us to continuously develop production.
4.) Fine blanking
The high temperatures and pressure of our “> 1000°C- die-casting process” create a circumferential burr along the separation plane of the mould. This is removed after cooling using the fine blanking process. Other stamping operations such as for example punching can be carried out in the same operation.
5.) CNC post-processing
Anything that cannot be cast completely requires supplementary post-processing work. We complete your component by boring, reaming, thread-cutting and milling.
Our economic objective for our customers, however, is the casting-compatible design of the component in the construction phase so that CNC post-processing is not necessary in the first place.
6.) Final quality inspection
We can take measurements without operator influence using the Keyence 3D measuring device and the Keyence Projector. Inspection is carried out during production using our universal tension-compression testing machine thus ensuring continuity in the mechanical properties of our castings.
Our CAQ system collects test data. FMEAs, machine capability analyses, process capability analyses and measuring device analyses are carried out in addition to further manufacturing statistical evaluations.
In addition to quality inspection during production, a final inspection takes place prior to delivery to the customer.
7.) Distribution
In order to achieve the greatest level of transparency, every operation is documented in the form of a process description. The linking of processes in a process map allows us to continuously optimise our processes.
The final step involves the delivery of the tested products to the customer.