Machining of castings

At ACTech, 'all in' means everything from a single source, no compromises and high speed across the entire process chain. We offer more than other foundries, because after casting, our work on your prototype is far from over. If you wish, we also take care of the machining of your parts: Along with metal casting, our CNC division is the heart of our company – and sets new standards in terms of diversity and performance.

In-house department for machining castings
Years of experience with extremely diverse parts spectrum
Premium CNC machining of parts in all sizes and geometries

For castings to become ready-to-assemble prototypes, further work steps are often required after treatment of the raw part: inserting assembly parts, assembling complex constructions – all this can only be achieved if precise machining has been previously performed. However, foundries do not normally offer this. We are the exception: As a proven problem solver, we take on the machining of castings for you, thus securing you major time advantages. How is that possible? Thanks to an interplay of innovative technology, state-of-the-art hardware and software and the extensive expertise of our specialists that has been acquired over many years.

We also have a tool and machine park second to none. Our outstanding, high-performance tool management enables the rapid, error-free CNC machining of your parts. Our gigantic inventory of tools also enables the machining of all materials we use for sand casting and metal 3D printing. This applies to both filigree, highly complex workpieces as well as large structural components.

Tools and machinery
Over 15,000 tool components and 900 unwinding heads with 24/7 availability
Material diversity
CNC milling and CNC turning for all materials used
Expertise
Specialized professionals with years of prototyping experience

Whether CNC milling or CNC turning – the machining of castings is preplanned with high precision from the start. For this purpose our technical experts use the latest CNC programs and simulation software (TEBIS and VERICUT), thus constantly probing the limits of feasibility for you. For maximum time and cost benefits we measure the parts outside the machine with optical 3D measurement technology. Our best-fit alignment in fixture construction and the use of intelligent shuttle table systems further save CNC machining time and achieve even more precise results.

Our CNC experts have a different part being machined each day. New challenges are our daily business, which is why we are capable of reliably tackling even highly complex components. After all, our experience gathered from producing 230,000 metal prototypes makes us the deserved front-runner. We always play it safe though and carry out extensive in-process measurements if required, because the CNC machining of castings is not about approximating but demands absolute precision in the micrometer range.

Individually optimized
Parts-matched fixture construction and best-fit alignment
Extensive simulations
Maximum machining precision thanks to simulated processes outside the machine
Newest machines
5-axis machining on state-of-the-art machines

Whether you need to implement your project in the last minute or have plenty of time for planning – for you there is no question of accepting compromises in terms of speed, safety and quality. This is why you should trust a professional who takes all relevant details into account from the start. At ACTech this is exactly what you get: Even before preparing a quotation, our experts take a close look at your component construction as part of a feasibility check with support from our experienced foundry and machining project management. For you this means zero risk, because when we accept your part including machining, we guarantee that we can actually implement your specifications.

Does it make sense to machine prototypes as milled parts from the solid?

Whether it is better to machine a prototype as a milled part, casting or 3D printed part depends on the geometry of the part, the material, the size, the quantity and even the function of the part. The production strategy of the subsequent batch part also plays a decisive role. If for example the subsequent batch part is a casting, the prototype should also be produced as a casting including machining.

When do metal 3D printed parts need to be machined?

In most cases the machining of 3D printed prototypes is necessary. When the accuracy of metal 3D printing is insufficient for tight tolerance or surface requirements, e.g. for fitting holes with tolerance H6, the combination of metal 3D printing and machining technologies offers significant advantages. Minimizing machining complexity through printing close to the contour is a further benefit of this technology combination.

How can short lead times for machining be ensured?

ACTech employs very well-trained specialists working in the field of CNC machining on state-of-the-art machines. Important preconditions for an optimal processing of prototype projects are the on-time provision of all information, programs and work equipment necessary for the machining. Thanks to our offline programming, the use of the interchangeable plate system, the equipping of workpieces and tools outside the machines and our perfectly organized tool management, we can ensure very short lead times in machining, thereby guaranteeing rapid delivery.

Can pre-assembled assemblies be machined?

Yes, fundamentally the sophisticated machining of pre-assembled assemblies, also called assembly machining, is possible at ACTech. An ACTech example of assembly machining with particularly high specifications is the CNC machining of a cylinder head with pressed-in valve seat inserts and valve guides.

Machining of castings

Precision and complexity:
machining of castings from a single source