Production and plant
Casting, heat treatment, machining, surface treatment and assembly on the same site. A part follows a defined route inside the plant; there is no intermediate transport, external waiting or uncertain lead time.
Production flow from raw material to shipment
The output of each station is taken over by the incoming inspection of the next.
- Raw material receiptMaterial certificate check, batch label
- CastingHPDC or sand casting, trimming
- Heat treatmentAgeing, case hardening, induction
- Precision machiningTurning, 5-axis milling, grinding
- Surface treatmentWashing, passivation, KTL, anodising
- MeasurementCoordinate measurement, leak tightness, hardness
- AssemblyPress fitting, torque control, function test
- ShipmentCustomer packaging, label, traceability record
A schematic plan of the site
The production groups are arranged by material flow; the measurement room sits between the casting and machining areas.
- 1Raw material receipt and warehouseIngot, bar and sheet intake; batch labelling.
- 2Casting cellsCold-chamber high-pressure die casting and sand casting line.
- 3Heat treatmentSolution treatment, ageing, case hardening and induction.
- 4Tool roomTool design, CNC machining, wire EDM and maintenance.
- 5Precision machiningCNC lathes, 5-axis machining centres, grinding and honing.
- 6Surface treatmentWashing, shot blasting, passivation and coating shipment preparation.
- 7Measurement roomCoordinate measurement, roughness, hardness and leak-tightness tests.
- 8Engineering officeSimulation, CAD/CAM and project management.
- 9Assembly and shippingPress fitting, torque-controlled assembly, packing and shipping.
Four groups, one route
Each group works with its own equipment and team; a part is passed between groups at defined stations inside the plant.
Casting
Cold-chamber high-pressure die casting cells and a sand casting line. Tool temperature and injection parameters are monitored per cell.
- Aluminium alloys: AlSi9Cu3, AlSi12, AlSi10Mg
- Grey and ductile iron: EN-GJL, EN-GJS
- Clamping force range: 400 – 1,600 t
- Integrated trimming and heat treatment
Precision machining
CNC lathes, 5-axis machining centres, cylindrical grinding and honing. Clamping fixtures are designed in the tool room.
- Machining tolerance: IT6 – IT9 (depending on the part)
- Surface roughness: Ra 0.4 – 3.2 µm
- Deep-hole and cross-channel machining
- In-process measurement and tool compensation
Tool room
Design, manufacture and maintenance of casting, injection and sheet-forming tools. Tool life and maintenance intervals are recorded.
- Gating and cooling design with casting simulation
- CNC machining and wire EDM
- Heat treatment of tool steel
- Trial shots and acceptance report
Assembly
Parts built into sub-assemblies. Press-fit force and torque values are recorded per part.
- Press fitting with force–displacement monitoring
- Torque- and angle-controlled fastening
- Robotic MAG welding
- Function test and laser DMC marking
A team that stays with you from design to series
If the part geometry is not suitable for casting or machining, we propose a revision together with the OEM's design team: wall thickness, draft angle, machining allowance and clamping surfaces. The aim is to lower scrap and rework rates from the start, before series production.
- Casting simulation and fill analysis
- CAD/CAM and fixture design
- Prototype and pre-series production
- Manufacturability feedback
The capacity and tolerance ranges given on this demo site are representative values written to show the level of information expected on sector websites.
Quality processes