Technical equipment
Construction
Design software
- Siemens NX
- incl.
CAM interface for NC machines - Reverse engineering with GeoMagic (reverse engineering)
Data exchange
- 3D data according to OFTP2
- Step / IGES / Pro-E
Casting simulation
- MAGMA-Soft
Model making
- Production of models in-house, rapid tooling
- Tactile measurement, Zeiss / Stiefelmeyer
- optical measurement (e.g. for tool life monitoring), GOM
Foundry
Melting process
- 2 hot blast cupola furnaces
- Melting capacity 15 t/h
- Casting furnaces on the molding lines
Materials
- Cast iron with lamellar graphite
- Cast iron with nodular graphite
Vertical molding line
- 1 DISAMATIC 2130 C
- Bale size 850 x 650 x 150 – 450 mm
- Casting weights up to 50 kg
Horizontal molding line
- 1 Heinrich Wagner-Sinto molding line
- Box size 1100 x 900 x 200 / 200 mm
- Casting weights up to 150 kg
Core manufacturing process
- Hot box and cold box
- Core shooters 12 – 40 liters
Coloring
On the way to the ready-to-install cast part, a surface coating is often required to ensure corrosion resistance and to meet the visual requirements of our customers.
Here, too, the specification must be closely coordinated with the customer in order to ensure efficient component realization.
- The color,
- the number of paint layers,
- the thickness of the varnish and
- optimally align the chemical properties of the coating to the usage requirements of the component.
We make sure that our coatings meet our customers’ requirements and are sustainable and environmentally friendly at the same time.
To this end, we focus primarily on water-soluble coatings.
In our foundry, we can paint or prime your parts on an overhead conveyor system.
In addition, we can also efficiently realize other customer requirements such as KTL coatings with external partners.
Your contact person is Ekrem Gürkale
Coloring
- Dipping (color bath)
- Painting (overhead conveyor)
- Water-based paints
Mechanical processing
We offer our customers the plus in casting and would like to offer our customers many value-added steps from a single source.
In addition to manufacturing the raw cast parts, we are also happy to take on the subsequent machining of the parts.
Our aim is to be able to supply the entire portfolio from a single source.
This reduces the complexity of our customers’ supply chain:
- Fewer suppliers
- Shorter process times
- Clear accountability
- Opportunity to optimize the entire value chain
- Lower logistics costs
We process the castings on more than 20 modern milling and turning machining centers in order to supply our customers with ready-to-install parts.
We are also happy to support our customers in their growth and invest in new machines in order to offer new processing and value-added scopes.
Your contact person is Uwe Strobl
20 Machining centers
- DMG DMC 63V
- 5x Heller H 2000 / 3x H 5000 / CP 6000 / 2x MCH 250 / MCH 280 / MCP 300
9 Lathes
- DMG CTX
- FFG Hessapp DVT 300 / 3x DVT 450 / DVT 750
- Heyligenstaedt Heynumat
Quality management
We want to offer our customers the highest level of quality and reliability.
To this end, we constantly monitor our processes from incoming goods and melting operations through to the raw part and the machined casting.
We take proactive measures to consistently avoid the repetition of errors.
Well-trained employees and modern measuring, testing and laboratory equipment form the basis for ensuring our quality standards:
Foundry testing equipment
- Spectrolab M12 spectral analysis
- Meltcontrol Heraeus/OCC
- Brinell hardness test
- Sand laboratory
- Ground joints / DHS
- Tensile strength Schenck
- Ultrasonic testing of wall thickness / coating thickness
Measuring equipment - Measuring machines Zeiss Contura, Zeiss / Stiefelmeyer
- Optical measurement GOM
- Statistics Q-DAS QS-Stat
We are DIN ISO 9001 certified and have other industry-specific certifications for our customers.
(Link Certifications)
Our claim is that our customers can ALWAYS rely on our component and delivery quality.
Your contact person is Jürgen Hanßmann
Foundry testing equipment
- Spectrolab M12 spectral analysis
- Meltcontrol Heraeus/OCC
- Brinell hardness test
- Sand laboratory
- Ground joints / DHS
- Tensile strength Schenck
- Ultrasonic testing of wall thickness / layer thickness
Measuring equipment
- Measuring machines Zeiss Contura, Zeiss / Stiefelmeyer
- Optical measurement GOM
- Statistics Q-DAS QS-Stat
Post-casting treatment
Your cast part receives the finishing touches in the casting post-treatment!
After solidification, the process of creating the optimum casting is not yet complete.
Further steps are required to fulfill customer requirements and deliver a usable casting.
We offer you the following processes for casting post-treatment:
- Rays
- Manual grinding
- Automatic grinding
The specific design depends on the requirements of the component.
The aim is always to meet the requirements of our customers as economically as possible.
Blasting the castings
During blasting, the castings are blasted with a metallic abrasive to remove deposits such as ore deposits, molding sand, core sand or scale and to achieve high-quality surfaces.
The blasting of castings is carried out in our foundry in three different systems, whereby we use interlinked systems to provide automated blasting with minimal handling:
- Horizontal blasting in the interlinked wire belt blast machine
- Suspended blasting in the interlinked overhead conveyor blast machine
- Troughed belt blast machine for barrel-shaped castings
Clean cast iron
After blasting, the cast parts are cleaned.
This involves removing excess parts from the castings and deburring them so that they are ready for installation or further processing.
In addition to manual fettling at our modern manual workstations, we also use Koyama grinding robots to fettle the castings efficiently and ergonomically and ensure a consistent fettling result for our customers.
Your contact person is Ekrem Gürkale
Foundry testing equipment
- Spectrolab M12 spectral analysis
- Meltcontrol Heraeus/OCC
- Brinell hardness test
- Sand laboratory
- Ground joints / DHS
- Tensile strength Schenck
- Ultrasonic testing of wall thickness / layer thickness
Measuring equipment
- Measuring machines Zeiss Contura, Zeiss / Stiefelmeyer
- Optical measurement GOM
- Statistics Q-DAS QS-Stat
Assembly
Thanks to our many years of experience in heating technology, we have built up a component production facility in which we integrate our customers’ cast parts into ready-to-install assemblies and components. In lean assembly lines with directly connected material supply for assembly material, we support our customers in focusing on their core competencies.
Our services range from the initial pre-assembly of cast parts to the assembly of ready-to-install functional modules, including the sourcing of assembly components. This is how we help our customers:
- Reduce your complexity in production
- Reduce inventories
- Utilize capacities and resources efficiently
On request, we can also carry out initial functional tests on our assembly lines.
Your contact person is Uwe Strobl