Develops and produces vent blocks, vacuum systems and metrology for die casting.
InterGuss Gießereiprodukte GmbH
Ipsheimer Straße 13, 91438 Bad WindsheimNew on Amplifa
About InterGuss
InterGuss Gießereiprodukte GmbH, based in Bad Windsheim, develops and sells vent blocks, vacuum systems and metrology for die casting foundries, toolmakers and suppliers to the automotive industry. The product range comprises the OptiVent, SVent, MiniVent and GigaVent series as well as the patented sawtooth vent block for slide insertion, complemented by the TopVac vacuum system for cold and hot chamber processes and the VacuCheck and CPMD measuring devices. The computer-aided design of the venting system is carried out using CFD flow simulation, CAD modelling and optimisation algorithms; the products are manufactured by audited partner companies. InterGuss has its own research and development department whose results are protected by numerous patents, including CPMD in-mould pressure measurement and the sawtooth geometry with a US patent. The company supplies more than 200 different types of venting systems to over 400 customers worldwide, including GM and Stellantis, and has been operating a training and development centre (application centre) at the Bad Windsheim site since 2018.
- Site
- Bad Windsheim
- Processes
- Die casting venting systems (vent blocks), Sawtooth vent block, OptiVent® vent block (pressure and vacuum applications), SVent® vent block (pressure and vacuum applications), GigaVent® vent block for machines >5000t, MiniVent® vent block for small moulds (pressure and vacuum applications), TopVac® vacuum system for cold and hot chamber processes, VacuCheck portable measuring device (pressure, flow rate, humidity)
- Materials
- Aluminium alloys, Magnesium alloys, Zinc, Tungsten steel (SVent insert), High thermal conductivity material (insert), High thermal conductivity material, CFD flow simulation, CAD modelling
- Certificates
- Process data recording (vacuum curves, shot data), Patented in-house metrology, ISO 9001
- Industries
- Die casting/Foundries, Toolmaking, Automotive suppliers
- 01
Workflow analysis and computer-aided design (CFD, CAD)
- 02
In-house research and development
- 03
Manufacturing by audited partner companies
- 04
Installation and commissioning
- 05
Training and on-site support, at the application centre or online
Materials & Processes
Aluminium alloys
Material for castings in the field of venting systems for pressure and vacuum applications.
Magnesium alloys
Material for castings for which the vent blocks are designed with reliable freezing.
Zinc
Material for small moulds, covered by the MiniVent series.
Tungsten steel (SVent insert)
Insert material with increased thermal conductivity and wear resistance.
High thermal conductivity material
Insert material for OptiVent and GigaVent, allowing larger vent cross-sections with reliable freezing.
CFD flow simulation
Computer-aided simulation of air and gas flow in the casting mould for the design of the venting system.
CAD modelling
Geometric modelling of the casting mould for the analysis of venting-relevant features.
Locations
Bad Windsheim
DEHead office with training and development centre (application centre)
- Part weight / size
- Vent blocks 0.03–60 kg part weight
- Lot size
- Special versions and series products
- Materials
- Aluminium, magnesium and zinc alloys, tungsten steel, high thermal conductivity materials
- TopVac® vacuum system (tank 300–3000 l, suction capacity 25–160 m³/h, <1 mbar abs.)
- VacuCheck portable measuring device
- CPMD in-mould pressure measurement system
- Thermal camera
- Blister oven
Products & Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Die casting venting systems (vent blocks)Casting | – | – | – | – | Aluminium, Magnesium, Zinc |
| Sawtooth vent blockCasting | – | – | – | – | Aluminium, Magnesium |
| OptiVent® vent block (pressure and vacuum applications)Casting | – | – | 0.3 kg – 60.0 kg | – | Aluminium, Magnesium |
| SVent® vent block (pressure and vacuum applications)Casting | – | – | 0.3 kg – 60.0 kg | – | Aluminium, Magnesium |
| GigaVent® vent block for machines >5000tCasting | – | – | – | – | Aluminium, Magnesium |
| MiniVent® vent block for small moulds (pressure and vacuum applications)Casting | – | – | 0.03 kg – 1.5 kg | – | Aluminium, Magnesium, Zinc |
| TopVac® vacuum system for cold and hot chamber processesCasting | – | – | – | – | – |
| VacuCheck portable measuring device (pressure, flow rate, humidity)Testing | – | – | – | – | – |
| CPMD in-mould pressure measurementTesting | – | – | – | – | – |
| Workflow analysis / computer-aided design of the venting system (CFD, CAD, optimisation)Engineering | – | – | – | – | – |
| Training on mould venting, mould design and die casting processesEngineering | – | – | – | – | – |
5 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Vacuum system | InterGuss TopVac® | – | Tank volume 300/500/1000/2000/3000 l; suction capacity 25/40/60/120/160 m³/h; final working | – | Bad Windsheim |
| Portable measuring device | InterGuss VacuCheck | – | – | – | Bad Windsheim |
| In-mould pressure measurement system | InterGuss CPMD | – | – | – | Bad Windsheim |
| Thermal camera | – | – | – | – | Bad Windsheim |
| Blister oven | – | – | – | – | Bad Windsheim |
Additional services
Reference customers
Quality
The TopVac systems store vacuum curves for quality assurance; the VacuCheck and CPMD measuring devices ensure process monitoring, leak testing and reproducible in-mould pressure measurement. In-house metrology technologies from R&D as well as a thermal camera and blister oven support consulting on casting evaluation and failure analysis.
| Evidence | Bad Windsheim |
|---|---|
| Process data recording (vacuum curves, shot data) | |
| Patented in-house metrology | |
| ISO 9001 |
History
- 2003
Market launch of the OptiVent® vent blocks
- 2005
First TopVac® vacuum system for 2 die casting machines with integrated flow rate measurement
- 2009
Delivery of the 1000th vent block in Germany
- 2011
New patented venting geometry
- 2013
Development of humidity sensor
- 2018
Opening of the training and development centre in Bad Windsheim
- 2019
Patent CPMD (in-mould pressure measurement)
- 2020
Patent sawtooth profile; later grant of the US patent for the sawtooth vent block
- 2024
Delivery of more than 200 different types of venting systems to over 400 customers worldwide