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Ready-to-install cast products in cast steel and spheroidal graphite cast iron with CNC machining and assembly group production
Wolfensberger AG
Bauma, CH · Bauma, CHNew on Amplifa
approx. 180Employees
2Plants in Bauma, Switzerland
100+Alloys in the materials portfolio
Ø 1200 mmMax. CNC turning diameter
800 kgMax. raw casting weight (hand moulding)
About Wolfensberger AG
Wolfensberger AG is a Swiss family-owned company based in Bauma (ZH), specialising in the manufacture of ready-to-install cast products in cast steel and spheroidal graphite cast iron. The company comprises two sites: its own foundry (Plant 1) and a plant for machining technology (Plant 2), enabling short distances from concept, casting to post-processing. In addition to conventional sand casting (hand moulding, semi-automatic production, core box process), Wolfensberger relies on innovative investment casting processes such as Ceracore® SHELF, Ceracore® Hybrid and Exacast®, which operate without wax and enable short lead times. The materials portfolio comprises over 100 alloys, including cast steel and spheroidal graphite cast iron, nickel alloys, Ni-Resist, wear-resistant castings, armoured steel, SiMo and silicon cast iron. In addition, the company offers CNC turning and milling, surface, plunge and profile grinding, die sinking, laser marking, toolmaking, pre-cast blanks as well as the assembly of complete assembly groups as general contractor. Around 180 employees manufacture for mechanical engineering and customers with highly stressed components and difficult-to-machine materials.
- Site
- CH-8494 Bauma
- Processes
- Investment casting with Ceracore® Shelf (fully ceramic investment casting process), Investment casting with Ceracore® Hybrid (sand casting process with ceramic inlays), Exacast® (fully ceramic production in the core package for heavy/large/thin-walled parts), Sand casting hand moulding (furan resin process), Sand casting semi-automatic production (cold-resin block moulding system), Core box process (Resol-CO2 process), Pre-cast blanks for CNC turning and milling (semi-finished products: cylinders, tubes, blocks; 3D, CNC turning (horizontal and vertical turning centres)
- Materials
- Spheroidal graphite cast iron / ductile iron, Cast steel (high-alloy), Nickel alloys, Ni-Resist (austenitic cast iron with 13–35 % nickel), Wear-resistant castings, Armoured steel, SiMo (silicon-molybdenum cast iron), Silicon cast iron
- Certificates
- 3D measurement / coordinate measurement
- Employees
- approx. 180
- Industries
- Mechanical engineering, Wear technology, Highly stressed components / difficult-to-machine materials, Special applications with special requirements
- 01
Casting-suitable design and materials consulting
- 02
Mould/core production (Ceracore®, Exacast®, sand casting)
- 03
Casting
- 04
Heat treatment (matched to the material)
- 05
CNC turning
- 06
CNC milling
- 07
Surface, plunge and profile grinding / EDM
- 08
Laser marking
- 09
3D measurement / coordinate measurement
- 10
Assembly of complete assembly groups
Locations
Bauma – Plant 1 Foundry
CHCasting production (Ceracore®, Exacast®, sand casting)
- Part weight / size
- Raw castings 1–800 kg (depending on process)
- Lot size
- Small series 1–10 (hand moulding), from 10 (semi-automatic), from 50 moulds
- Materials
- Steel and iron castings, up to 100 iron and cast steel materials
- Sand casting hand moulding furan resin process (flask 2000 x 2000 mm)
- Cold-resin block moulding system (1200 x 1200 x 840 mm)
- Core box process Resol-CO2 (800 x 800 x 400 mm)
- Ceracore® SHELF automated production lines
- Ceracore® Hybrid automation line
- Toolmaking
Bauma – Plant 2 Machining Technology
CHCNC machining, grinding, EDM, measurement, assembly
- Part weight / size
- Turning up to Ø 1200 mm / 800 mm turning length
- Lot size
- Small to medium series (pendulum operation, multiple setups)
- Materials
- Cast steel, spheroidal graphite cast iron, nickel alloys, hardfacing cast iron, hard metals, ceramics
Components
Inside the production
Industries
Mechanical engineeringWear technologyHighly stressed components / difficult-to-machine materialsSpecial applications with special requirements
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Investment casting with Ceracore® Shelf (fully ceramic investment casting process)Casting | – | – | – | – | Cast steel, Spheroidal graphite cast iron, Nickel alloys, Ni-Resist, Wear-resistant castings, Armoured steel, SiMo, Silicon cast iron |
| Investment casting with Ceracore® Hybrid (sand casting process with ceramic inlays)Casting | – | – | – | – | Cast steel, Spheroidal graphite cast iron, Nickel alloys, Ni-Resist, Wear-resistant castings |
| Exacast® (fully ceramic production in the core package for heavy/large/thin-walled parts)Casting | – | – | – | – | Cast steel, Iron and cast steel materials |
| Sand casting hand moulding (furan resin process)Casting | – | 2000 mm × 2000 mm | 5 kg – 800 kg | 1 – 10 | up to 100 iron and cast steel materials |
| Sand casting semi-automatic production (cold-resin block moulding system)Casting | – | 1200 mm × 1200 mm × 840 mm | 5 kg – 200 kg | 10 | up to 100 iron and cast steel materials |
| Core box process (Resol-CO2 process)Casting | – | 800 mm × 800 mm × 400 mm | 1 kg – 50 kg | 50 moulds | up to 100 iron and cast steel materials |
| Pre-cast blanks for CNC turning and milling (semi-finished products: cylinders, tubes, blocks; 3DCasting | – | – | – | – | Cast steel, Spheroidal graphite cast iron, Nickel alloys, Ni-Resist, Wear-resistant castings |
| CNC turning (horizontal and vertical turning centres)Machining | – | Ø 1200 mm | – | – | Cast steel, Spheroidal graphite cast iron, difficult-to-machine materials |
| CNC milling (multi-axis milling centres, pendulum operation, multiple setups)Machining | – | – | – | – | Steel, Spheroidal graphite cast iron, Hardfacing cast iron |
| Grinding (surface, plunge and profile grinding)Machining | – | – | – | – | wear-resistant steels, hard metals, ceramics |
| Assembly of complete assembly groups incl. procurement of purchased partsAssembly | – | – | – | – | – |
| Engineering / casting-suitable design and materials consultingEngineering | – | – | – | – | – |
| EDM (die sinking)Machining | – | 1070 mm × 735 mm × 450 mm | 800 kg | – | – |
| Laser markingSurface | – | – | – | – | – |
| Heat treatment (matched to wear-resistant casting alloys)Heat treatment | – | – | – | – | Wear-resistant castings |
28 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| CNC 2-spindle vertical turning machine | HESSAPP DV 122 (Sinumerik 3T/3TT) | 1 | Swing diameter Ø 1300 mm, turning diameter Ø 1200 mm, turning length 800 mm, 60 kW | – | Bauma |
| CNC 4-axis vertical turning machine | Doosan V850T (Fanuc 18i TB) | 2 | Swing Ø 1000 mm, turning diameter Ø 850 mm, turning length 850 mm, 30 kW each | – | Bauma |
| CNC 4-axis vertical turning machine | Doosan Puma V400-2SP (Fanuc 31i A) | 1 | Swing Ø 496 mm, turning diameter Ø 400 mm, turning length 461 mm, 2 spindles 22 kW each | – | Bauma |
| CNC 2-axis vertical turning machine | Doosan Puma V8300 (Fanuc F0i-T) | 2 | Swing Ø 850 mm, turning diameter Ø 830 mm, turning length 750 mm, 45 kW | – | Bauma |
| CNC slant-bed turning machine | Victor V-Turn-A26 (Fanuc 0i-TD) | 1 | Swing Ø 700 mm, turning diameter Ø 350 mm, turning length 910 mm, 22 kW | – | Bauma |
| CNC slant-bed turning machine | Victor V-Turn-36 (Fanuc 18-T) | 1 | Swing Ø 650 mm, turning diameter Ø 500 mm, turning length 1255 mm, 40 kW | – | Bauma |
| CNC slant-bed turning machine | Victor V-Turn-V40 (Fanuc 21i-TB) | 1 | Swing Ø 720 mm, turning diameter Ø 500 mm, turning length 2000 mm, 37 kW | – | Bauma |
| CNC turning machine | Storebro STB 2000 (Sinumerik 810 T) | 1 | Swing Ø 410 mm, turning diameter Ø 260 mm, turning length 660 mm, 22 kW | – | Bauma |
| Die sinking EDM machine | AgieCharmilles Agietron Integral 3 (4-axis CNC, 28-position electrode changer) | 1 | Clamping area 800 x 600 mm, max. workpiece height 500 mm, working tank 1070 x 735 x 450 mm, max. | – | Bauma |
| Marking laser | Electrox Maxbox Plus 1 | 1 | – | – | Bauma |
| Coordinate measuring machine | Wenzel | 1 | 2400 x 1200 x 800 mm | – | Bauma |
| Coordinate measuring machine | Mora | 1 | 1000 x 1200 x 800 mm | – | Bauma |
| Measuring arm (scanning and tactile measurement) | Faro | 1 | – | – | Bauma |
| CNC column-type machining centre, 5-axis | Ibarmia ZHV-42/3000 (Heidenhain TNC 530i) | 1 | X 3000 / Y 800 / Z 800 mm, rotary table Ø 800 mm, 60 tool positions HSK63 | – | Bauma |
| CNC horizontal machining centre | OKK HM 63 (Fanuc 16i MC) | 1 | X 1000 / Y 850 / Z 820 mm, pallet 630 x 630 mm, 120 tool positions | – | Bauma |
| CNC horizontal machining centre | OKK HM 500 (Fanuc 31i Model A5) | 1 | X 630 / Y 620 / Z 710 mm, pallet 500 x 500 mm, 120 tool positions BT50 | – | Bauma |
| CNC horizontal 5-axis machining centre | Heller HF-5500 APC (Siemens 840D) | 1 | X 900 / Y 950 / Z 900 mm, 2 pallets 500 x 630 mm, 100 tools HSK-100 | – | Bauma |
| Bed milling machine | Heller PFU 3 (Pro NC 80-C) | 1 | X 1800 / Y 710 / Z 800 mm, 24 tools SK50 | – | Bauma |
| CNC vertical machining centre | Doosan DNM 4500 (Fanuc F0i-T) | 1 | X 800 / Y 450 / Z 510 mm, 30 tools BT-40 | – | Bauma |
| CNC universal tool milling machine | Mikron WF 61C (Heidenhain TNC 355) | 1 | X 800 / Y 500 / Z 460 mm, 18 tools ISO 40 | – | Bauma |
| CNC vertical milling machine | Bridgeport XR1000 (Fanuc 18iMB) | 1 | X 1020 / Y 610 / Z 610 mm, 24 tools SK40 | – | Bauma |
| Surface, plunge and profile grinding machine | Mägerle F-12-V-R-S1 | 5 | 1200 x 320 x 300 mm | – | Bauma |
| Surface, plunge and profile grinding machine | Mägerle F-120-S4.11 | 1 | 1200 x 500 x 500 mm | – | Bauma |
| Surface, plunge and profile grinding machine | Mägerle F-100-R | 1 | 1000 x 500 x 500 mm | – | Bauma |
| Surface, plunge and profile grinding machine | Mägerle FPK-10-S4.2 | 1 | 1000 x 320 x 500 mm | – | Bauma |
| Surface, plunge and profile grinding machine | Mägerle FDK-15-S4.2 | 1 | 1500 x 320 x 300 mm | – | Bauma |
| Surface grinding machine | Blohm Precimat 306 (easy Touch) | 1 | 600 x 300 x 450 mm | – | Bauma |
| Grinding machine | Strausak 57 W | 2 | 500 x 250 x 175 mm | – | Bauma |
Additional services
Foundry-oriented consulting / casting-suitable designMaterial selection consultingToolmakingCNC turning (up to Ø 1200 mm)CNC milling (3–5 axes)Surface, plunge and profile grindingPre-cast blanks / semi-finished partsAssembly of complete assembly groups (general contractor)Engineering supportProduct developmentEDMLaser marking3D measurement / coordinate measurementHeat treatment (matched to material selection for wear-resistant castings)
Quality
The machine-finished parts are inspected using coordinate measuring machines (Wenzel 2400 x 1200 x 800 mm, Mora 1000 x 1200 x 800 mm) as well as a Faro measuring arm (scanning and tactile measurement). Machining is carried out on stable CNC machines with control of demanding tolerances and high surface finishes.
| Evidence | Bauma – Plant 2 Machining Technology |
|---|---|
| 3D measurement / coordinate measurement |