CNC machining of long aluminium extrusion profiles, aluminium welding and assembly manufacturing from prototype production through to series production.
Mack Alu-Systeme GmbH
Klettgau-GeisslingenNew on Amplifa
About Mack Alu-Systeme
Mack Alu-Systeme GmbH is a machining company for long and large-volume aluminium extrusion profiles as well as complex structural components made of aluminium and steel. The company produces high-precision CNC machining of profiles up to 8 m in length on SPC-monitored horizontal machining centres with rotary tables, which are designed for series parts of 500 to 10,000 units. In addition, the company offers aluminium welding using TIG, TIG-AGL and MIG processes, robotic welding for series components, and the assembly of modules up to complete assemblies. In-house CAD design, in-house toolmaking and comprehensive project management complement the range of services from concept development through prototype production to just-in-time delivery including supply chain management. Customers include companies from the aerospace industry, mechanical engineering, the automotive and rail vehicle sectors, electrical engineering/electronics, the construction industry, the solar industry as well as shipbuilding and yacht construction. The company headquarters with production is located in Klettgau-Geisslingen in the district of Waldshut.
- Site
- Klettgau
- Processes
- CNC milling of aluminium extrusion profiles, CNC machining on horizontal CNC machining centres with rotary tables (SPC-monitored), Aluminium welding (TIG, TIG-AGL, MIG), Robotic welding for series production, MIG and TIG manual welding for small series and one-off productions, Welded constructions, Assembly manufacturing (modules up to complete assemblies), Surface finishing (e.g. anodising, surface treatment)
- Materials
- Aluminium, Aluminium extrusion profiles, Steel (steel and aluminium load-bearing structures in accordance with DIN 1090-1), Steel
- Certificates
- DIN EN ISO 9001:2015, EN 9100:2018 (eq. AS 9100D), DIN EN 15085-2 (rail vehicle construction), DIN EN ISO 3834-2, EN 1090 / DIN 1090-1 (steel/aluminium load-bearing structures), ISO 9001, EN 9100, EN 1090, Other, ISO 14001, ISO 13485
- Industries
- Aerospace industry, Mechanical engineering, Automotive, Rail vehicles, Electrical engineering/Electronics, Construction industry
- 01
Design and CAD design
- 02
Material procurement (extrusion plants)
- 03
CNC milling/machining
- 04
Aluminium welding (TIG, MIG, robotic)
- 05
Surface finishing (via partners/extrusion plants)
- 06
Cleaning
- 07
Assembly manufacturing
- 08
Quality assurance
- 09
Just-in-time logistics
Materials and Processes
Aluminium
The company's main material for CNC-machined profiles, welded constructions and assemblies.
Aluminium extrusion profiles
Sourced from national and international extrusion plants, machining up to 8 m in length.
Steel
Execution of steel and aluminium load-bearing structures in accordance with DIN 1090-1.
Locations
Klettgau-Geisslingen
DEHeadquarters / Production
- Part weight / size
- Profile machining up to 8 m in length
- Lot size
- Series parts 500–10,000 units
- Materials
- Aluminium, steel
- AXA VHC 3-S (2×, travel 8000×3750×700 mm, 4/5-axis)
- AXA VHC 3-XTS
- DMG MORI DMF220 / DMF220L
- DMG MORI DMU95 monoBlock (5-axis)
- DMG MORI DMU75 monoBlock (5-axis)
- DMG MORI DMU85 monoBlock (5×, 5-axis)
- DMG MORI DMF400-11
- DMG MORI DMP70 (2×)
- Chiron FZ 15 KS (5×)
- Chiron Mill 6000 high speed (travel 6000×2730 mm)
- Chiron Mill 8000 high speed (travel 8000×3730 mm)
- Chiron FZ 16 S five axes
- Welding robots for series production
- Semi-automatic cleaning system (700×1400×3000 mm)
Components and Assemblies
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| CNC milling of aluminium extrusion profilesMachining | – | 8 m | – | 500 units – 10,000 units | Aluminium |
| CNC machining on horizontal CNC machining centres with rotary tables (SPC-monitored)Machining | – | 7 m | – | 500 units – 10,000 units | Aluminium |
| Aluminium welding (TIG, TIG-AGL, MIG)Joining | – | – | – | – | Aluminium, Steel |
| Robotic welding for series productionJoining | – | – | – | – | Aluminium |
| MIG and TIG manual welding for small series and one-off productionsJoining | – | – | – | – | Aluminium |
| Welded constructionsJoining | – | – | – | – | Aluminium |
| Assembly manufacturing (modules up to complete assemblies)Assembly | – | – | – | – | Aluminium |
| Surface finishing (e.g. anodising, surface treatment)Surface | – | – | – | – | Aluminium |
| Semi-automatic water-soluble cleaningSurface | – | 3000 mm × 1400 mm × 700 mm | – | – | Aluminium |
| In-house CAD design / toolmaking / engineering from idea to series productionEngineering | – | – | – | – | Aluminium |
| Testing: VT (visual testing), PT (dye penetrant testing), MT (magnetic particle testing),Testing | – | – | – | – | Aluminium |
13 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Horizontal CNC machining centre (4/5-axis) | AXA VHC 3-S | 2 | 8000 x 3750 x 700 mm | 2014 | Klettgau Geisslingen |
| Horizontal CNC machining centre (4/5-axis) | AXA VHC 3-XTS | 1 | 3000 x 1250 x 1100 mm | 2022 | Klettgau Geisslingen |
| Universal machining centre | DMG MORI DMF220 | 1 | 2200 x 900 x 560 mm | 2003 | Klettgau Geisslingen |
| Universal machining centre | DMG MORI DMF220L | 1 | 2200 x 900 x 560 mm | 2006 | Klettgau Geisslingen |
| 5-axis machining centre | DMG MORI DMU95 monoBlock | 1 | 950 x 850 x 650 mm | 2023 | Klettgau Geisslingen |
| 5-axis machining centre | DMG MORI DMU75 monoBlock | 1 | 750 x 650 x 560 mm | 2024 | Klettgau Geisslingen |
| 5-axis machining centre | DMG MORI DMU85 monoBlock | 5 | 935 x 850 x 650 mm | 2025 | Klettgau Geisslingen |
| Universal machining centre | DMG MORI DMF400-11 | 1 | 4000 x 1100 x 1200 mm | 2025 | Klettgau Geisslingen |
| Machining centre | DMG MORI DMP70 | 2 | 700 x 420 x 380 mm | 2025 | Klettgau Geisslingen |
| CNC machining centre | Chiron FZ 15 KS | 5 | 730 x 400 x 360 mm | 2012 | Klettgau Geisslingen |
| CNC machining centre | Chiron Mill 6000 high speed 341-40 | 1 | 6000 x 2730 x 610 mm | 2017 | Klettgau Geisslingen |
| CNC machining centre | Chiron Mill 8000 high speed 309-81 | 1 | 8000 x 3730 x 820 mm | 2019 | Klettgau Geisslingen |
| 5-axis machining centre | Chiron FZ 16 S five axes | 1 | 660 x 660 x 400 mm | 2019 | Klettgau Geisslingen |
Additional services
Quality and Certifications
The quality management system has been certified since 1996; inspections include VT (visual testing), PT (dye penetrant testing), MT (magnetic particle testing) and macroscopic structural examinations, accompanied by welding engineers.
| Evidence | Klettgau-Geisslingen |
|---|---|
| ISO 9001 | |
| EN 9100 | |
| EN 1090 | |
| Other | |
| ISO 14001 | |
| ISO 13485 |
Company History
- 1996
Company certified for quality management