WH 10000 for Megacasting Machining in E-Mobility

Improved cost-efficiency Wenzler and Benz join forces to optimise megacasting machining

2026-08-13 Source: Benz Tooling 2 min Reading Time

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August Wenzler Maschinenbau, a Heller company, and Benz Tooling are joining forces to take the machining of megacasting components for e-mobility to a new level.

Benz Tooling 5-axis heads in a WH 10000 5-axis machining center from August Wenzler Maschinenbau, a company of the Heller Group. The fourth and fifth axes are housed in the 5-axis head, allowing both units to operate with a high degree of freedom of movement.(Source: Benz Tooling) — Benz Tooling 5-axis heads in a WH 10000 5-axis machining center from August Wenzler Maschinenbau, a company of the Heller Group. The fourth and fifth axes are housed in the 5-axis head, allowing both units to operate with a high degree of freedom of movement.
(Source: Benz Tooling)

The transformation of the automotive industry calls for new manufacturing technologies. In the field of e-mobility, large-format aluminium structural components — known as “megacastings” — are becoming increasingly important. These complex components replace hundreds of individual parts, reduce weight, and drastically shorten assembly times. At the same time, they demand the highest standards in machining due to large machining volumes, long cycles, and the need for the highest precision.

August Wenzler Maschinenbau, based in Spaichingen/germany, has taken on this challenge. With its WH 10000 series, the company offers a machine platform specifically designed for machining large aluminium castings. Combined with Benz Tooling’s 5-axis heads, motor-spindles, and angle heads, the result is a solution that improves precision and productivity significantly.

Gallery

Synergy for maximum productivity and flexibility. The 5-axis head, integrated motor spindle, and exchangeable unit are a perfect match.(Source: Benz Tooling)

Precision machining of a megacasting component(Source: Benz Tooling)

Simultaneous machining for maximum productivity

The WH 10000 horizontal 5-axis machining center is based on a robust dual-spindle design. Two linear 3-axis units are positioned opposite each other and machine a centrally clamped workpiece in parallel from two sides. This allows large megacasting components, such as front or rear subframes, to be fully machined in a single setup.

The workpiece is mounted on a horizontal swivel axis. The fourth and fifth axes are housed in the Benz milling heads, ensuring maximum freedom of movement. Integrated motor spindles with speeds of up to 16,000 rpm (HSK-A63) ensure stable machining. Each unit features a magazine for 51 tools with a fast pick-up changer. The WH 10000 can be fully automated and utilizes efficient minimum-quantity lubrication as well as digital drives for low-maintenance operation.

Key component for precision and dynamics

The Benz 5-axis head enables simultaneous control of all axes for hard-to-reach contours. Its rigid design and highly dynamic drives ensure precise positioning. Inside, position measurement systems track the positions of all relevant components, while IO-Link signal transmission provides status data such as temperature and speed for diagnostic purposes. The rotary distributor with slip ring technology guarantees reliable media and power transmission during rotation.

The integration of three core technologies from Benz Tooling — the 5-axis head, motor-spindle, and angle head — creates a perfectly coordinated system unit. This technology partnership enables automakers to make the paradigm shift to megacasting highly productive and cost-effective.

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