Die casting tool manufacturing GF Casting Solutions optimizes tool production with Emco CNC technology

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At GF Casting Solutions Altenmarkt, the use of CNC turning machines from Emco is supporting efficient spare parts production for die casting tools. This approach helps reduce setup times, streamline processes, and ensure on-demand availability of precision components in the automotive sector.

GF Casting Solutions Altenmarkt in Styria, Austria, specialises in magnesium and aluminium die casting solutions for the international automotive industry. With around 650 employees, the company is an important regional employer in the field of light metal die casting in Austria and beyond. The company was founded in 1972 and has been one of 12 GF Casting Solutions AG production sites around the world since 1999.

The aluminium and magnesium die cast parts produced are mainly developed for the bodies, interiors and drive systems of premium cars sold worldwide. The focus here is on lightweight construction and ready-to-install solutions. The demands on the tools, which weigh up to 70 tons, are constantly increasing. Fast set-up times are a key factor here.

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CNC turning machines from Emco, based in Hallein, near Salzburg, are used to manufacture the spare parts required for the die casting tools. The Hyperturn 65 Powermill G2 is used here, along with the Emcoturn E65 CNC turning centre, which was added this year. ‘From the first technical discussions to the sales process and delivery, our collaboration with Emco went extremely well. Besides, I have been familiar with Emco machines since my training days, and we know that we are buying machines that deliver what they promise and perform very well in terms of precision,’ says Thomas Klade, team leader of GF Casting Solutions.

“Both machines are perfectly tailored to our requirements and run excellently. The support from Emco is also really good,” says Klade. The Emcoturn E65 turning centre is used primarily to produce screw cores. “With this machine, GF Casting Solutions has been able to significantly reduce its machining times. The parts are collected in a pot and unloaded via the partial conveyor belt, which also eliminates the need to open the door. A bar loader can also be installed, which enables partially autonomous production,” explains Leopold Zerz, Head of Sales for Emco in Austria. He also emphasises how positive the collaboration with GF Casting Solutions is.

GF Casting Solutions has a high demand for the screw cores to be produced. The company is broadly positioned with the foundry in Altenmarkt and is pleased that the Emcoturn E65 turning centre has taken its internal spare parts management to the next level. Screw cores are now also produced in-house and stored for employees to remove as needed.

Regarding the special features of the machine, Mr. Leopold Zenz reveals: “It is a universal turning machine with a 65 mm spindle passage, counter spindle, radial turret with twelve driven tools, as well as a Y-axis with 80 mm stroke.”

One of the biggest advantages of this purchase is definitely the time saved. ”For example, if the system is given the order to produce 15 pieces, these are produced fully automatically within a certain period and engraved according to the requirements of our plant in Altenmarkt. They are then ejected onto a conveyor belt. No further manual intervention is required, and we have been able to reduce production time by two-thirds,” says Thomas Klade.

The Emco Hyperturn 65 Powermill G2, which was purchased in 2022, is also doing its job to the client’s complete satisfaction. “Thanks to this machine, we have been able to minimise and simplify the work steps. The set-up and clamping times have been significantly reduced and we can produce very efficiently,” says Thomas Klade.

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