Three ways to the component

The Basic variants include solutions with standard tools that cover the requirements for the production of prototypes or small batches at low cost. The investment required is comparatively low and the use of tools is flexible. As many changes are often made to the component and process in this phase, the flexibility gained with standard tools is very helpful. The use of special tools is avoided wherever possible in the Basic solution.

The Performance solution is geared towards series production and focuses on the machining of specific components with special tools. The workpiece can be machined more efficiently with step and combination tools than with the Basic variant. The Performance solution enables reliable production suitable for series production without having to meet the highest quality and productivity requirements.

This is reserved for the Expert variant. It contains solutions that enable certain components to be machined productively and effectively with as few tools as possible in a short cycle time with the best possible quality. Typical here is the use of multi-bladed and multi-stage tools in which all functional features are combined in one tool. One example of an Expert solution is the tool set for machining the stator housing for an electric motor, which Mapal has already successfully established in the industry. In terms of productivity and quality, Mapal has reached the limits of performance with these tools. In addition, there is also a basic and a performance solution for the production of the stator housing, with which the demands made at the respective stages are met.

Sophisticated parts for the electric car

In addition to the electric drive, Mapal is also focusing on other components of the electric car. These include auxiliary units such as the scroll compressor for thermal management as well as housings for the power electronics and battery frames. Many milling operations are required for the latter, which can also be easily represented in the three-part Basic-Performance-Expert concept. Comparatively simple standard tools are sufficient for trials or small quantities. The next stage is special solid carbide tools that combine several machining steps and ensure reliable machining. In the performance area, milling cutters with special coatings or PCD milling cutters are then used to increase tool life to a higher level.

Mapal clarifies the optimum solution for the respective requirement situation in direct dialog with the customer. In many cases, the customer may only use two of the three possible stages. This is because prototype production often takes place at specialized machining companies, so that the OEM starts directly with series production. If the quality requirements are met and the productivity is sufficient for the quantities to be produced, a machining solution from the performance variant is used. It may also not place such high demands on machine performance, which can be a criterion when converting existing lines to e-mobility. Of course, a manufacturer can also switch directly from prototype production to a machining solution from the performance variant if, for example, the costs per component are the primary consideration above a certain production volume.

Open and targeted communication with the customer has always been the focus at Mapal. Because only an open dialog makes it possible to offer the right individual tool solution for every application and every customer.