CNC contract manufacturing and ECM machining: deburring, polishing, chamber electrolysis and spray hole radiusing as well as ECM machine and plant engineering.
KSMA GmbH - Maschinen- und Anlagenbau
74214 Schöntal-BieringenNew on Amplifa
About KSMA
KSMA GmbH is a company founded in 1992 by Karl-Heinz Sitzler in Schöntal-Bieringen in the Hohenlohe district. Originally specialized in the development and construction of special machines, fixtures and complete systems, today the focus is on CNC contract manufacturing and ECM services (electrochemical deburring, polishing, contour machining, chamber electrolysis). The combination of CNC machining and ECM processes enables the delivery of ready-to-install parts and assemblies from lot size 1 to large-scale series. A key focus is ECM spray hole radiusing, among other things with the newly developed Flowtec2 machine for precision spray hole radiusing with high flow accuracy. Customers come from automotive, aircraft engineering and aviation, chemicals and pharmaceuticals, the food industry and mechanical engineering. In addition, KSMA offers ECM machine and plant engineering, fixture construction, training and simultaneous engineering with its own design in 2D/3D CAD/CAM.
- Site
- Schöntal-Bieringen
- Processes
- CNC milling (5-axis), CNC machining 4-axis, CNC turning, ECM deburring (electrochemical), ECM polishing, ECM contour machining (chamber electrolysis), ECM spray hole radiusing (Flowtec2, flow accuracy approx. ±3% at 100 bar), ECM machine and plant engineering (special machine construction)
- Materials
- Aluminum, Materials of all grades (general, for CNC machining), Steel, Materials of all grades, Electrochemical Machining (ECM)
- Certificates
- Operator self-inspection, 3D metrology
- Founded
- 1992
- Industries
- Automotive, Aircraft Engineering & Aviation, Chemicals & Pharmaceuticals, Mechanical Engineering, Food Industry, Apparatus Engineering
- 01
Simultaneous engineering (2D/3D CAD/CAM design, feasibility studies,
- 02
Tool and fixture construction
- 03
CNC milling (4-/5-axis) and CNC turning
- 04
ECM machining (deburring, polishing, contour machining, chamber electrolysis,
- 05
3D metrology / quality control
- 06
Assembly and delivery of ready-to-install parts and assemblies
Materials & Processes
Aluminum
Material for CNC-milled parts and for the electrochemical machining of edges, boreholes and spray holes.
Steel
For large diesel engine components and series parts in CNC and ECM machining.
Materials of all grades
CNC contract manufacturing processes materials of all grades.
Electrochemical Machining (ECM)
Workpiece as anode, tool electrode as cathode; material is electrochemically dissolved in the electrolyte gap - without thermal or mechanical stress.
Locations
Schöntal-Bieringen
DEHeadquarters and manufacturing
- Lot size
- Prototype (lot size 1) to large-scale series
- Materials
- Materials of all grades, aluminum, steel
- 5-axis machining centers: 2x DMG DMU 60 evo, 3x DMG DMU 80 evo, 1x DMG DMU 100 evo, 5x Grob G550
- 5x CNC lathes (Spinner)
- 4-axis machining centers: 3x Matsuura H+405 (6-fold pool), 4x Matsuura H+504 (Fastems pallet storage), 1x Matsuura H+504 (6-fold pool)
- 4 programming stations
- ECM machines: 5x KSMA standard up to 4,000 A, 4x KSMA double station up to 2,000 A
- ECM spray hole radiusing machine Flowtec2
- 3D measuring machine Zeiss Contura
- Surface measuring device Zeiss Surfcom
- Measuring machine Keyence XM
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| CNC milling (5-axis)Machining | – | – | – | Lot size 1 (prototype) – Large-scale series | Materials of all grades |
| CNC machining 4-axisMachining | – | – | – | Small series – Large-scale series | Materials of all grades |
| CNC turningMachining | – | – | – | – | – |
| ECM deburring (electrochemical)Surface | – | – | – | Series production (minimum machining – Large-scale series | Aluminum, Steel (electrolyte process generally) |
| ECM polishingSurface | – | – | – | – | – |
| ECM contour machining (chamber electrolysis)Surface | – | – | – | – | – |
| ECM spray hole radiusing (Flowtec2, flow accuracy approx. ±3% at 100 bar)Surface | Flow accuracy approx. ±3% (at 100 bar) | – | – | – | Aluminum (spray hole nozzles, high-pressure nozzles), Steel (large diesel engine components) |
| ECM machine and plant engineering (special machine construction)Engineering | – | – | – | – | – |
| ECM fixture construction / toolmakingEngineering | – | – | – | – | – |
| Simultaneous engineering (CAD/CAM, 2D and 3D design, feasibility studies, prototypes)Engineering | – | – | – | Lot size 1 | – |
| 3D metrology / quality controlTesting | – | – | – | – | – |
| Assembly / delivery of ready-to-install parts and assemblies (pre-assembled)Assembly | – | – | – | – | – |
15 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| 5-axis machining center | DMG DMU 60 evo | 2 | – | – | Schöntal-Bieringen |
| 5-axis machining center | DMG DMU 80 evo | 3 | – | – | Schöntal-Bieringen |
| 5-axis machining center | DMG DMU 100 evo | 1 | – | – | Schöntal-Bieringen |
| 5-axis machining center | Grob G550 | 5 | – | – | Schöntal-Bieringen |
| CNC lathe | Spinner | 5 | – | – | Schöntal-Bieringen |
| 4-axis machining center | Matsuura H+405 (with 6-fold pool) | 3 | – | – | Schöntal-Bieringen |
| 4-axis machining center | Matsuura H+504 (with Fastems pallet storage) | 4 | – | – | Schöntal-Bieringen |
| 4-axis machining center | Matsuura H+504 (with 6-fold pool) | 1 | – | – | Schöntal-Bieringen |
| Programming station (CNC programming) | – | 4 | – | – | Schöntal-Bieringen |
| 3D measuring machine | Zeiss Contura | – | – | – | Schöntal-Bieringen |
| Surface measuring device | Zeiss Surfcom | – | – | – | Schöntal-Bieringen |
| Measuring machine | Keyence XM | – | – | – | Schöntal-Bieringen |
| ECM machine (standard, up to 4,000 A) | KSMA Standard | 5 | – | – | Schöntal-Bieringen |
| ECM machine (double station, up to 2,000 A) | KSMA Double station | 4 | – | – | Schöntal-Bieringen |
| ECM spray hole radiusing machine | KSMA Flowtec2 | – | – | – | Schöntal-Bieringen |
Additional services
Reference customers
Quality
Quality control is carried out, among other things, through operator self-inspection as well as with 3D metrology: Zeiss Contura and Zeiss Surfcom as well as a Keyence XM measuring machine.
| Evidence | Schöntal-Bieringen |
|---|---|
| Operator self-inspection | |
| 3D metrology |
History
- 1992
Founding of KSMA by Karl-Heinz Sitzler; specialization in the development and construction of special machines, fixtures and complete systems. Later focus on CNC contract manufacturing and ECM services.
- ca. 2000er
Development of ECM spray hole radiusing machines for large diesel engines, high-pressure nozzles and refill nozzles with a flow accuracy of approx. ±3% at 100 bar.
New development Flowtec2: ECM machine for precision spray hole radiusing with very high flow accuracy.