• MAPAL's technology centre at the headquarters in Aalen.
  • The engineers of the Technology Expert Team at MAPAL specialize in the complete planning of special components.
  • Machining solutions for complete workpieces from MAPAL.

Gaining technological lead with engineering services by MAPAL

As an engineering partner, MAPAL accompanies its customers from the planning to the optimisation of the production. They can select from service modules as required, or make use of service packages specially tailored to their needs.

In both cases, MAPAL experts with many years of experience place their high level of innovation and their holistic perspective of processes at the customers' disposal. 
The technology centre with its state-of-the-art equipment is able to exactly simulate every production process, allowing the specialists to find new, even better solutions for the customers.
The engineering specialists work deeply into the customer's processes.

Services tailored to different initial situations

  • Designing a new manufacturing line

    MAPAL takes over the project planning for your complete workpieces and plans and realises a reliable process – quickly, flexibly, on-site, with transparent costs and complete documentation.
    Customers can concentrate on their core competence. 

  • Re-tooling the manufacturing for new parts

    Continuing to use existing machines saves time and costs. With many years of experience and know-how MAPAL guarantees the highest process reliability.
    The specialists support individually according to customer needs and, upon request, take over the complete responsibility for the re-tooling.

  • Optimising tools and processes during on-going production

    Introducing modern machining strategies and innovative tool solutions during on-going production also represents a considerable potential for increases in productivity.
    The result: longer tool lives, improved part quality and increased productivity.

Engineering service modules

  • The MAPAL specialists analyze a component in detail.

    E1 - Project analysis

    Based on raw part and finished part drawings as well as machine data, MAPAL analyses the manufacturing task in close collaboration with the customer and develops effective machining strategies for all steps.

    The project analysis includes:
    • Machining proposals for all machining steps
    • Tool list
    • Tool sketches
    • Feasibility study
    • Harmonisation with the machine situation
    • Preparation of bore and surface plans

  • Well-founded design of the machining process by specialists from MAPAL.

    E2 - Process design

    Irrespective of whether the focus is on flexibility or productivity: with a sound design of the machining process, MAPAL supports its customers on the way to stable, economic manufacturing.

    Elements of process design:
    • Cycle time studies
    • Definition of technology data
    • Division of process over individual machines
    • Clamping principle sketches

  • he engineering specialists at MAPAL define the optimal tools for the customer's process.

    E3 - Tool solutions

    Outstanding performance, simple handling, cost-effective reconditioning: MAPAL specifically selects or develops the best, latest, cost-effective tools for the application.

    Elements of the tool solutions module:
    • Tool design
    • Tool engineering
    • Combination tools for reducing process steps
    • Design of clamping technology
    • Tool drawings
    • Assembly, setting and balancing (at MAPAL)
    • Delivery to the place of use
    • Professional support during breaking-in

  • The engineering specialists at MAPAL adapt the documentation to the individual customer.

    E4 -Documentation

    Upon request, the documentation prepared as part of the engineering services is specifically adapted to customers' requirements. This ensures the rapid implementation of the new processes and makes future changes easier.

    Documentation services:
    • Setting plans
    • Tool plans
    • Setting and installation instructions
    • Work instructions
    • Inspection and measurement logs/reports
    • Trials logs
    • Process capability reports

  • Clamping concepts are also part of the engineering services from MAPAL.

    E5 - Fixture solutions

    With individual solutions MAPAL ensures that as many workpieces and as many machining steps as possible can be reliably machined with μ-precision in one clamping system.

    Options within the module fixture solutions:
    • Preparation of drafts
    • Engineering
    • Manufacture/buying-in
    • Assembly and commissioning
    • Technical support
    • Pre-acceptance with clamping trial

  • Tool restriction studies are part of MAPAL's engineering services.

    E6 - Tool restriction study

    To prevent collisions and to identify optimisation potential, MAPAL simulates the planned machining process in advance and based on 3D models in a virtual environment.

    Tool restriction studies comprise:
    • Collision analyses
    • 3D study
    • Optimal harmonisation of tools to fixture, workpiece and machine compartment
    • Prerequisite: virtual models of tools, workpiece, clamping fixture and machine

  • Im Engineeringbereich optimiert MAPAL auch die Bearbeitungsparameter der NC-Programmierung.

    E7 - NC Programming

    To design the process as productive as possible, MAPAL optimises the machining parameters during NC programming. In this way secondary activities such as loading/unloading and tool change can be accelerated.

    Elements in the module NC programming:
    • Preparation of NC program taking into account manufacturer-specific machine functions 
    • Preparation of special milling cycles (e.g. interpolation turning, trochoidal milling) 
    • Computer-based generation of machining contours (2D/3D)
    • Customer-specific program structure

  • MAPAL übernimmt vor Ort die Inbetriebnahme und das Einfahren des Kundenprozesses.

    E8 - Einfahren und Inbetriebnahme

    Damit die Kunden sicher und ohne Ausschuss produzieren können, übernimmt MAPAL vor Ort die Inbetriebnahme und das Einfahren des Prozesses. Bei engen Terminplänen kann das Einfahren auch im MAPAL Technologiezentrum erfolgen.

    Services beim Einfahren und Inbetriebnehmen:
    • Überprüfung und Protokollierung der Maschinengeometrie
    • Installation der NC-Technologie
    • Einfahren des kompletten Bearbeitungsprozesses
    • Vorbereitung und Durchführung der Prozessfähigkeitsuntersuchung
    • Übergabe Prozess an den Kunden

  • Beim Anlauf der Fertigung unterstützt MAPAL seine Kunden.

    E9 - Anlaufunterstützung

    Auch beim Anlauf der Fertigung unterstützt MAPAL seine Kunden vor Ort. Für eine möglichst produktive und kostengünstige Fertigung kontrollieren die Zerspanungsspezialisten dabei kontinuierlich die Standzeiten und Schnittwerte der Werkzeuge.

    ​​​​​​​Optionen der Anlaufunterstützung:​​​​​​​​​​​​​​
    • Unterstützung beim Fertigungsanlauf
    • Troubleshooting
    • Technischer Support
    • Schulung in Bedienung, Programmierung und Prozessablauf

  • Komplette Bearbeitungslösungen für das Kundenbauteil erarbeitet das Technology Expert Team von MAPAL.
  • Das Bild zeigt die wesentlichen Werkzeuglösungen eines MAPAL Komplettpakets für die Bearbeitung eines Lenkrohrs.
  • Im MAPAL Technologiezentrum in Aalen steht Kunden eine reale Fertigungsumgebung zur Verfügung.

  • Lösungen für komplette Werkstücke

    Das Servicepaket Technology Expert Team TET umfasst in der Regel die Engineeringmodule 1 bis 4. Die TET-Spezialisten übernehmen die Projektierung kompletter Bauteile, die Kunden profitieren von der langjährigen Engineeringerfahrung.

  • Prozessauslegung und Umsetzung aus einer Hand: re.tooling

    Für die Erstausrüstung oder Umrüstung eines bestehenden Maschinenparks bietet MAPAL das Servicepaket re.tooling an. Dieses Paket besteht in der Regel aus den Bausteinen 1–9, wird jedoch individuell an die Bedürfnisse angepasst.

  • Reale Fertigungsumgebung für den Kunden: das MAPAL Technologiezentrum

    Prozesse simulieren, testen und einfahren ohne eigene Kapazitäten zu binden, dafür bietet das MAPAL Technologiezentrum eine reale Fertigungsumgebung mit 11 modernen Bearbeitungszentren, Schleifmaschine, hochpräziser Messtechnik sowie die Möglichkeit zur additiven Fertigung. 50 Ingenieure und Techniker unterstützen und begleiten die Kunden von der Idee bis zur Realisierung vor Ort.