Machinery – CNC milling, turning and EDM at one location
What a manufacturing operation can deliver is decided by its machines – and by how well they work together. This page lists our complete machinery: 20 CNC-controlled machines, plus grinding, metrology room, cutting and finishing.
Everything sits at one single site in Brotterode-Trusetal. A component never leaves the building between two operations.
We assess feasibility and get back to you promptly.
Manufacturing depth at one location
Twelve CNC machining centres, nine of them with full 5-axis simultaneous kinematics. Two turning centres with driven tools and a counter spindle. Six EDM machines for contours that no milling cutter can reach.
Added to that: surface, cylindrical and vibratory grinding, our own metrology room, cutting, and the complete finishing process through to particle-free packaging.
The component range runs from under one gram to eight tonnes: the Deckel Maho DMU 210P machines workpieces up to 2,100 × 1,800 × 1,250 mm.
Automated manufacturing around the clock
Four machining centres run inside robot cells – three EROWA systems and one Indunorm installation – with 228 pallet positions in total. Once the process parameters are dialled in, they keep producing overnight and at weekends without an operator.
That moves the economic threshold downwards: smaller batch sizes can be costed without set-up time dictating the unit price. A CNC saw in automatic mode prepares the cutting for series parts unattended as well.
Tolerances from 1 to 5 µm – and the proof to match
Five of our Fehlmann machining centres work to a repeatability of under 3 µm, with spindle speeds up to 20,000 rpm. That is the machine side.
The other side is the proof. Our metrology room houses a Zeiss CONTURA G4 with a scanning probe and a measuring uncertainty of 2.0 + L/350 µm for components up to 1,200 × 1,800 × 800 mm. Alongside it a Zeiss DURA MAX, an optical measuring projector from Keyence and around 500 fit and thread gauges.
Only both together produce a tolerance that is not merely achieved, but documented.
Materials that others turn down
Titanium, Inconel, Hastelloy, Invar and Kovar are part of our standard range, as is the machining of hardened parts by hard milling. Where a milling cutter can no longer reach, EDM takes over – with surface finishes down to Ra 0.1 µm and taper cuts up to ± 30°.
For UHV and cleanroom-compatible components, ultrasonic cleaning completes the process chain.
The machines in detail
Source document: machine list FB 713-306, version 08.
CNC machining centres
| Machine | Axes | Travel / clamping area | Control | Spindle | Equipment |
|---|---|---|---|---|---|
| Fehlmann Picomax P90 M | 5 axes simultaneous | 705 × 425 × 610 mm | Heidenhain iTNC 530 | 20,000 rpm | EROWA robot cell, 90 ITS148 pallets + 10 UPC pallets · repeatability < 3 µm |
| Fehlmann Picomax P90 M | 5 axes simultaneous | 705 × 425 × 610 mm | Heidenhain TNC 430 | 18,000 rpm | EROWA robot cell, 40 ITS148 pallets · repeatability < 3 µm |
| Fehlmann Picomax P90 M | 5 axes simultaneous | 705 × 425 × 610 mm | Heidenhain TNC 430 | 18,000 rpm | Repeatability < 3 µm |
| Fehlmann Picomax P60 M | 5 axes simultaneous | 530 × 350 × 610 mm | Heidenhain iTNC 530 | 20,000 rpm | EROWA robot cell, 60 ITS148 pallets · repeatability < 3 µm |
| Fehlmann Picomax P60 | 3 axes | 530 × 350 × 610 mm | Heidenhain TNC 430 | 16,000 rpm | Repeatability < 3 µm |
| Deckel Maho DMU 210P | 5 axes simultaneous | 2,100 × 1,800 × 1,250 mm | Heidenhain iTNC 530 | 12,000 rpm | Max. workpiece weight 8 tonnes |
| Deckel Maho 125 P | 5 axes simultaneous | Clamping area 1,250 × 880 × 800 mm | Heidenhain iTNC 530 | 12,000 rpm | — |
| Deckel Maho DMU 80 P hidyn | 5 axes simultaneous | Rotary table Ø 900 mm | Mill Plus | 18,000 rpm | — |
| DMU 80 Evolution | 5 axes simultaneous | Clamping area 800 × 700 mm | Heidenhain iTNC 530 | 18,000 rpm | — |
| DMG Mori 80 Evolution | 5 axes simultaneous | Clamping area 800 × 700 mm | Heidenhain iTNC 640 | 20,000 rpm | Indunorm robot cell, 28 pallets 500 × 500 × 360 mm |
| Fehlmann Picomax 54 | NC, 2.5 axes | 500 × 260 × 160 mm | Heidenhain TNC 320 | 7,100 rpm | Repeatability < 10 µm |
| Fehlmann Picomax 20 | NC, 2.5 axes | 450 × 260 × 110 mm | — | 6,300 rpm | Repeatability < 10 µm |
CNC turning
| Machine | Axes | Capacity | Control | Equipment |
|---|---|---|---|---|
| DMG CTX 500 Beta | 4 axes | Ø 230 mm · spindle bore 67 mm | Heidenhain TurnPlus | Turret with 12 tool stations, all driven |
| Gildemeister CTX 410 | 3 axes | Ø 200 mm · spindle bore 55 mm | Siemens ShopTurn | Turret with 12 tool stations, all driven |
Die-sinking and wire EDM
| Machine | Process | Travel | Control | Workpiece and features |
|---|---|---|---|---|
| Charmilles Roboform 51 | Die-sinking EDM | 600 × 400 × 450 mm | Fanuc | 24-position tool changer |
| Charmilles Robofil 330F | Wire EDM | 400 × 300 × 400 mm | Fanuc | Workpiece up to 900 × 600 × 400 mm · taper cuts up to ± 30° · water bath with automatic wire threading |
| GF AGIE Charmilles Progress VP3 | Wire EDM | 500 × 350 × 426 mm | AC Vision 5 | Workpiece up to 900 × 600 × 426 mm · taper up to ± 30° · surface finish Ra 0.2 µm · water bath with automatic wire threading |
| Agie Charmilles CUT 3000 | Wire EDM | 500 × 350 × 256 mm | AC Vision 5 | Workpiece up to 900 × 600 × 256 mm · taper cutting unit U/V 70 mm · surface finish Ra 0.1 µm |
| Charmilles HD 8 | Start-hole EDM | 350 × 250 × 280 mm | Heidenhain position control | Workpiece up to 650 × 300 × 200 mm · start hole Ø 0.5–3.0 mm |
| GF Drill 20 | CNC start-hole EDM | 300 × 200 × 300 mm | Easy Drill CNC | Workpiece up to 250 × 180 × 200 mm · start hole Ø 0.5–3.0 mm |
Grinding
| Machine | Process | Capacity | Note |
|---|---|---|---|
| Jung JF625 | Surface grinding | Table 600 × 250 mm · height 180 mm | — |
| Okamoto ACC-105DX | Surface grinding | Table 1,000 × 500 mm · height 500 mm | Table load up to approx. 500 kg |
| Studer RM 250 | Cylindrical grinding | up to Ø 50 mm · centre distance 200 mm | Small parts |
| TOS BUA 20A | Cylindrical grinding | up to Ø 200 mm · centre distance 450 mm | — |
| Rösler | Vibratory finishing | up to 500 × 200 × 150 mm | Fine vibratory finishing of the most delicate precision-part geometries |
Quality control
| Device | Type | Measuring range | Probe | Accuracy |
|---|---|---|---|---|
| Zeiss CONTURA G4 1000 RDS | Bridge-type CMM | 1,200 × 1,800 × 800 mm | VAST XXT TL3, scanning | Measuring uncertainty 2.0 + L/350 µm |
| Zeiss DURA MAX | 3D coordinate measuring machine | 400 × 400 × 400 mm | VAST XXT, scanning | Measuring uncertainty 2.4 + L/300 µm · surface roughness measurement |
| Keyence IM-6120 | Digital measuring projector | Measuring field 100 × 200 mm | optical | ± 5 µm, with stitching ± (7 + 0.02 L) µm |
| Mitutoyo LH-600 E/EG | Height gauge | Granite plate 600 × 600 mm | tactile | 1.1 + 0.6 L/600 µm |
| Fit and thread gauges | Gauge inspection | — | — | approx. 500 different gauges |
Cutting, sheet metal and finishing
| Machine | Process | Capacity | Note |
|---|---|---|---|
| Behringer HBP 313 A | CNC sawing | Cutting width 500 mm · cutting height 300 mm | Automatic mode for unattended cutting of series parts · accuracy 0.1 mm |
| Panel saw | Cutting aluminium and plastics | Height max. 30 mm · width max. 1,000 mm | — |
| Schröder MHSU 2000/3.0 | Guillotine shear | Cutting width up to 2,030 mm | Sheet thickness 0.5–3.0 mm |
| Schröder MAK II 2000/3.5 | Folding machine | Sheet width up to 2,030 mm | Sheet thickness 0.2–3.5 mm · bending angle up to 140° |
| Micropeen 1400 ZP | Sand blasting | 1,500 × 500 × 500 mm | Media: corundum and glass beads |
| Micromat 1200 S/FP | Sand blasting | 600 × 400 × 300 mm | Media: glass beads |
| Sablux | Sand blasting | 200 × 200 × 150 mm | Media: glass beads |
| Sonoswiss ultrasonic system | Ultrasonic parts cleaning | 450 × 270 × 200 mm | Cleaning for UHV and cleanroom-compatible components |
CAD and CAM
| Software | Scope | Application |
|---|---|---|
| SolidWorks Professional | CAD | Design, with SolidWorks Enterprise PDM for data management |
| TransMagic Pro | CAD | Format conversion for common CAD formats |
| Surfcam Advanced 2A + 5A | CAM | 2D, 3D and simultaneous machining |
| hyperMILL | CAM | 2D, 3D and simultaneous machining |
| Camtek PEPS | CAM | Wire EDM programming |