Prototypes for automobile construction
Highly complex parts with maximum speed
The automotive industry is the engine of the European economy. This is where concentrated expertise, short development cycles and maximum quality specifications come together. To survive as a manufacturer in the market, top speed and maximum precision are already specified in prototype production – and in view of climate change this factor applies today more than ever. At ACTech, we have the necessary horsepower under the hood: we have been producing castings for the automotive industry, ranging from exhaust manifolds with integrated turbochargers to cylinder heads, for more than two decades.
Short development cycles demand the fastest possible production of new prototypes.
The complexity of casting prototypes assumes wide expertise as well as special technologies in the processing of challenging geometries and materials.
Current global challenges such as climate change and the energy crisis constantly lay the basis for new requirements.
Reliable, fast and innovative – forging a common path with ACTech means you always have an ace up your sleeve. In the world of prototype production, we're a front-runner and problem solver in one: Thanks to optimized process flows, highly efficient technologies and efficiently trained specialist personnel, we radically reduce production times. And that's not all: When other foundries shy away from special materials or highly complex part geometries, we're just warming up. Our expertise is amply demonstrated by our milestones: more than 230,000 metal prototypes and over 25 years of experience in the production of castings for the automotive industry and other sectors – we know what we're doing and we continuously develop further. Whether crankcases or gearbox housings, structural components, exhaust manifolds or components for alternative drives – our innovative strength speaks for itself.
Cylinder heads, crankcases and turbochargers with and without exhaust manifolds have been a part of our core business for many years. We also increasingly manufacture structural components: Frames, carriers and nodes that combine several functions and thus reduce assembly complexity and weight are mandatory in today's automotive construction. Do you have even more complex requirements? We can also produce your electric drives, cylinder heads, crankcases and much more at record speed and in premium quality – fully machined, tested and ready for installation.
Are reliability and quality your top priorities? Then we share a common belief. This is why, as a manufacturer of castings for the automotive industry, we have TISAX® certification. This confirms that since 2015, the information management of ACTech GmbH has met the requirements of the German Association of the Automotive Industry (VDA). Furthermore, we have certification as a welding enterprise in accordance with DIN 3834-2 and our quality and environmental management systems are audited in accordance with ISO 9001 and ISO 14001 respectively.
Is ACTech certified according to IATF 16949?
Certification according to IATF 16949 is often required by OEMs in the automotive industry for suppliers of series parts. The specifications for the quality management system are based on EN ISO 9001. The ACTech GmbH quality management system is certified compliant to ISO 9001 by the TÜV SÜD Management Service GmbH certification center. These certificates are valid for the production and distribution of castings as prototypes, single parts, spare parts and small batches, including CNC machining.
How are castings changing in the automotive industry?
In addition to the familiar combustion engine designs, increasingly complex gearbox housings, electrified axles, e-motors and structural components are being developed for new vehicle concepts. Requirements such as savings in weight and the optimization of installation space are leading to thinner wall thicknesses and more complex geometries. The choice of suitable materials is also increasingly being focused on.
What specifications does the automotive industry place on delivery times?
The automotive industry was and remains the driver for fast delivery times. Our in-house production enables us to respond effectively to the needs of on-time delivery and fastest possible production times. By offering all necessary manufacturing steps from casting to finished part machining, as well as supplementary services such as the mounting of assembly parts or coatings, our customers have the advantage of receiving everything from a single source. Thus, delivery times for prototypes are cut by several weeks.
Have unit numbers changed for development projects in the automotive industry?
In the prototype sphere we are experiencing an increase in the number of units for development projects. In particular, new concepts for alternative drive technologies are often requested with a higher number of prototype parts. We are witnessing a trend from formerly typical prototype lot sizes of 1-3 parts to 5-10 pieces, as needed for initial setups. There has also been a noticeable increase in demand for small batches of several hundred units.