Germany

K e e p o n e s t e p a h e a d .
ACTech GmbH
Halsbrücker Str. 51 R i g h t f r o m t h e s t a r t .
09599 Freiberg/Sa.
Germany
Phone: +49 3731 169 0
Fax: +49 3731 169 500
E-Mail: prototype@actech.de
www.actech.de

USA

ACTech North America Inc.

4343 Concourse Drive, Suite 350
Ann Arbor, MI, 48108
USA
Phone: +1 734 913 0091
Fax: +1 734 913 0095
E-Mail: info@rapidcastings.com
www.rapidcastings.com

India

ACTech GmbH Liaison Office

No 15/2, Sangama, Diagonal Road
Vasantnagar
Bangalore - 560 052
India
Phone: +91 80 41131342
Fax: +91 80 41131343
E-Mail: prototype@actech.in
www.actech.in

RAPID CASTINGS®

E n g l i s h v e r s i o n

www.actech.de
 ACTech GmbH
ACTech designs and produces casting prototypes and
small batches for customers from various industries: for
the automotive industry and its suppliers, for the
aerospace industry, for machine and plant manufacturers.
As one of the leading global rapid prototyping companies,
OVERVIEW we provide all design and production processes, under
one roof, necessary for the speedy production of a
complete casting prototype. From the 3D data set, we
produce complete castings which are ready to be installed
and tested. State-of-the-art rapid prototyping processes,
combined with CNC pattern making and CNC machining,
provide for extremely fast production of prototypes that,
from the very first casting, are comparable to series
production.

Engineering
Locations: Freiberg, Germany
Ann Arbor, USA
Bangalore, India

Design Production area: 6,500 sqm

additional 1,700 sqm under construction
additional 1,000 sqm planned

Personnel: more than 300 (30 % graduate engineers)

Mold production - sand casting Customers: over 900 customers worldwide in 33 countries

Output annual: up to 2,500 different prototype parts with

up to 15,000 castings

Mold production - investment casting Certification: to ISO/TS 16949 and EN ISO 14001
for development and production of
prototype castings and small batches,
including machining

Prototype Foundry

Raw Part Inspection

CNC Machining

Samples

Our expertise benefits our customers by reducing

Service development time and lowering costs compared to using
conventional methods. The result is a smooth production
launch for our customers. Today, more than 900
companies worldwide utilize our unique service.
 ACTech GmbH
ACTech designs and produces casting prototypes and
small batches for customers from various industries: for
the automotive industry and its suppliers, for the
aerospace industry, for machine and plant manufacturers.
As one of the leading global rapid prototyping companies,
OVERVIEW we provide all design and production processes, under
one roof, necessary for the speedy production of a
complete casting prototype. From the 3D data set, we
produce complete castings which are ready to be installed
and tested. State-of-the-art rapid prototyping processes,
combined with CNC pattern making and CNC machining,
provide for extremely fast production of prototypes that,
from the very first casting, are comparable to series
production.

Engineering
Locations: Freiberg, Germany
Ann Arbor, USA
Bangalore, India

Design Production area: 6,500 sqm

additional 1,700 sqm under construction
additional 1,000 sqm planned

Personnel: more than 300 (30 % graduate engineers)

Mold production - sand casting Customers: over 900 customers worldwide in 33 countries

Output annual: up to 2,500 different prototype parts with

up to 15,000 castings

Mold production - investment casting Certification: to ISO/TS 16949 and EN ISO 14001
for development and production of
prototype castings and small batches,
including machining

Prototype Foundry

Raw Part Inspection

CNC Machining

Samples

Our expertise benefits our customers by reducing

Service development time and lowering costs compared to using
conventional methods. The result is a smooth production
launch for our customers. Today, more than 900
companies worldwide utilize our unique service.
 Engineering
E n g i n e e r i n g
The know-how for designing and optimizing new
cast parts that meet all of the customers´
requirements is the result from the production of up
to 2,500 different casting prototypes per year. We
are able to immediately review development stages
with the help of modern simulation software.
Comparing simulation parameters with the
simultaneously produced prototypes additionally
assures the realized results. Successful
developments in the areas of engines and
powertrains are only a few examples as to how
manufacturers benefit from working with ACTech.
Product- and Process development
- full function development and optimization of castings
including manufacturing of prototypes and small batches
- failure mode and effect analysis
- computer aided design in 3D and preparation of drawings
- development of new cast technologies
- support for series production
Simulation
- fluid mechanics
- coupling of fluid and heat with Ansys CFD
- structural mechanics
- structural dynamics
- thermical simulation with Ansys
- mold filling and solidification simulation with internal stress
and porosity forecast
Reverse Engineering
- optical scanning with GOM 3D scanner
- dimension measuring by 3D coordinate measuring technology
- area redesign with Geomagics software
- 3D designing supported by sketches and drawings
- adaptation tests of reconstructed parts following the function and
manufacturing process
- raw and machined part design and drawing preparation
 Engineering
E n g i n e e r i n g
The know-how for designing and optimizing new
cast parts that meet all of the customers´
requirements is the result from the production of up
to 2,500 different casting prototypes per year. We
are able to immediately review development stages
with the help of modern simulation software.
Comparing simulation parameters with the
simultaneously produced prototypes additionally
assures the realized results. Successful
developments in the areas of engines and
powertrains are only a few examples as to how
manufacturers benefit from working with ACTech.
Product- and Process development
- full function development and optimization of castings
including manufacturing of prototypes and small batches
- failure mode and effect analysis
- computer aided design in 3D and preparation of drawings
- development of new cast technologies
- support for series production
Simulation
- fluid mechanics
- coupling of fluid and heat with Ansys CFD
- structural mechanics
- structural dynamics
- thermical simulation with Ansys
- mold filling and solidification simulation with internal stress
and porosity forecast
Reverse Engineering
- optical scanning with GOM 3D scanner
- dimension measuring by 3D coordinate measuring technology
- area redesign with Geomagics software
- 3D designing supported by sketches and drawings
- adaptation tests of reconstructed parts following the function and
manufacturing process
- raw and machined part design and drawing preparation
D e s i g n

Design
CAD - Systems Interface formats
By adding machining allowance, we produce raw - CATIA - STEP
- Pro/E - IGES
part datasets from our customers machined part - UniGraphics - VDA-FS
datasets for the following production. If the - ACIS
- and others
customer provides the raw part data in addition to
the machined part data, these are checked and complete periphery
150 sqm for CAD department
adjusted if necessary. After layout, design and
sometimes simulation of the gate and feeder
system, the mold parting line is determined. 3D
CAD data from the released mold segments and
cores are used to produce the molds in the various
processes.
D e s i g n

Design
CAD - Systems Interface formats
By adding machining allowance, we produce raw - CATIA - STEP
- Pro/E - IGES
part datasets from our customers machined part - UniGraphics - VDA-FS
datasets for the following production. If the - ACIS
- and others
customer provides the raw part data in addition to
the machined part data, these are checked and complete periphery
150 sqm for CAD department
adjusted if necessary. After layout, design and
sometimes simulation of the gate and feeder
system, the mold parting line is determined. 3D
CAD data from the released mold segments and
cores are used to produce the molds in the various
processes.
 Mold production for
sand casting
Rapid production of molds for highly complex and
core-intensive castings is made possible by
ACTech. By using innovative rapid prototyping
technologies that allow mold production without the
need for patterns for the initial prototypes.
Supplemented by the options of CNC pattern
making, we are offering our customers a cost
effective method to quickly produce even higher
quantities.
Laser Sintering of Croning®- Material
- 6 EOSint S 700/750 machines
dimension of platform: 720 x 380 x 380 mm
- 2 EOSint S 350 - machines
dimension of platform: 350 x 350 x 520 mm
- 420 sqm production area
Direct Mould Milling®
- 2 Simultaneous 5-axis HSC milling machines
max. mold segment dimension: 2,400 x 1,400 x 800 mm
- 150 sqm production area

Laser Sintering of
Croning®- Material
ACTech offers high precision and an almost
unlimited degree of geometric freedom in the
design of mold segments and cores with the laser
sintering of Croning®- Material. Based on the 3D
CAD data from the mold design, we use rapid
prototyping processes to produce ready to use
cores and mold segments within a very short
c a s t i n g

period of time.

Direct Mould Milling - DMM®

We offer a fast and affordable solution for very
large and complex parts as well. With direct mold
s a n d

milling, we produce mold segments and also cores

from a prepared mold material block on CNC
milling centers. A single DMM® mold segment from
this method can be up to 2.5 meters long. Further
-

segmenting of the mold then provides almost

p r o d u c t i o n

unlimited large casting molds and rapid prototyping

with completely new dimensions.
M o l d
 Mold production for
sand casting
Rapid production of molds for highly complex and
core-intensive castings is made possible by
ACTech. By using innovative rapid prototyping
technologies that allow mold production without the
need for patterns for the initial prototypes.
Supplemented by the options of CNC pattern
making, we are offering our customers a cost
effective method to quickly produce even higher
quantities.
Laser Sintering of Croning®- Material
- 6 EOSint S 700/750 machines
dimension of platform: 720 x 380 x 380 mm
- 2 EOSint S 350 - machines
dimension of platform: 350 x 350 x 520 mm
- 420 sqm production area
Direct Mould Milling®
- 2 Simultaneous 5-axis HSC milling machines
max. mold segment dimension: 2,400 x 1,400 x 800 mm
- 150 sqm production area

Laser Sintering of
Croning®- Material
ACTech offers high precision and an almost
unlimited degree of geometric freedom in the
design of mold segments and cores with the laser
sintering of Croning®- Material. Based on the 3D
CAD data from the mold design, we use rapid
prototyping processes to produce ready to use
cores and mold segments within a very short
c a s t i n g

period of time.

Direct Mould Milling - DMM®

We offer a fast and affordable solution for very
large and complex parts as well. With direct mold
s a n d

milling, we produce mold segments and also cores

from a prepared mold material block on CNC
milling centers. A single DMM® mold segment from
this method can be up to 2.5 meters long. Further
-

segmenting of the mold then provides almost

p r o d u c t i o n

unlimited large casting molds and rapid prototyping

with completely new dimensions.
M o l d
c a s t i n g

CNC Pattern Making

s a n d

CNC Pattern Making

By combining the rapid prototyping technologies
with the options from the CNC pattern making, we
are also realizing higher quantities for pilot and
-
- 1 unit: 3,000 x 2,000 x 700 mm maximal pattern size;
5-axis milling center
- 2 units: 2,000 x 1,000 x 650 mm maximal pattern size;
3-axis milling center

- 2 units: 1,600 x 800 x 650 mm maximal pattern size;

small batches quickly and economically. Depending 3-axis milling center
p r o d u c t i o n

on the quantities needed and the required delivery

time, optimum production technologies can be
selected for each application using a break-even
approach.
Mold Assembly
- 3D measuring system (Zett-Mess)
- optical measuring system (GOM)
- 2 drying chambers for cores up to 200 °C
- 270 sqm production area

Mold Assembly
By using tactile and optical measuring techniques
M o l d

to monitor the process in the mold assembly, we

ensure adherence to tolerances which would not
be possible with the conventional sand casting.
With this method and directional solidification in the
sand casting mold, material properties and cast
part tolerances are achieved that can easily
withstand the comparison with series production in
die casting.
c a s t i n g

CNC Pattern Making

s a n d

CNC Pattern Making

By combining the rapid prototyping technologies
with the options from the CNC pattern making, we
are also realizing higher quantities for pilot and
-
- 1 unit: 3,000 x 2,000 x 700 mm maximal pattern size;
5-axis milling center
- 2 units: 2,000 x 1,000 x 650 mm maximal pattern size;
3-axis milling center

- 2 units: 1,600 x 800 x 650 mm maximal pattern size;

small batches quickly and economically. Depending 3-axis milling center
p r o d u c t i o n

on the quantities needed and the required delivery

time, optimum production technologies can be
selected for each application using a break-even
approach.
Mold Assembly
- 3D measuring system (Zett-Mess)
- optical measuring system (GOM)
- 2 drying chambers for cores up to 200 °C
- 270 sqm production area

Mold Assembly
By using tactile and optical measuring techniques
M o l d

to monitor the process in the mold assembly, we

ensure adherence to tolerances which would not
be possible with the conventional sand casting.
With this method and directional solidification in the
sand casting mold, material properties and cast
part tolerances are achieved that can easily
withstand the comparison with series production in
die casting.
 Mold production for
Model making
investment casting - vacuum chamber with wax pouring equipment
- 2 air conditioned rooms for controlled cooling and storage
Laser sintered master patterns or wax parts of wax positives
- 150 sqm production area
produced with silicone tools are the first steps in
investment casting process. Together with the gate Plaster technology
and feeder system, the mounted clusters with - vacuum chamber with automatic plaster mixer
- 9 furnaces for burning out of plaster cuvettes
mineralized or ceramic mold material are - 650 sqm production area
assembled to a complete investment casting mold.
ACTech not only casts aluminum, but also iron and Ceramic technology
steel alloys in rapid prototyping investment casting. - 3 slurry tanks
- 2 sand showers and one shell dryer
- one gas oven CGH850 for curing of ceramic molds
- 650 sqm production area
c a s t i n g
i n v e s t m e n t
-
p r o d u c t i o n
M o l d
 Mold production for
Model making
investment casting - vacuum chamber with wax pouring equipment
- 2 air conditioned rooms for controlled cooling and storage
Laser sintered master patterns or wax parts of wax positives
- 150 sqm production area
produced with silicone tools are the first steps in
investment casting process. Together with the gate Plaster technology
and feeder system, the mounted clusters with - vacuum chamber with automatic plaster mixer
- 9 furnaces for burning out of plaster cuvettes
mineralized or ceramic mold material are - 650 sqm production area
assembled to a complete investment casting mold.
ACTech not only casts aluminum, but also iron and Ceramic technology
steel alloys in rapid prototyping investment casting. - 3 slurry tanks
- 2 sand showers and one shell dryer
- one gas oven CGH850 for curing of ceramic molds
- 650 sqm production area
c a s t i n g
i n v e s t m e n t
-
p r o d u c t i o n
M o l d
 Prototype Foundry
F o u n d r y
ACTech operates several melting furnaces for
aluminum, iron and steel alloys in its own foundry
center. This provides the flexibility to not only
realize up to 200 prototype projects at the same
time, but also to cast an assembled mold in less
than one hour. With the help of the vacuum-
P r o t o t y p e
supported casting technique, we are able to
achieve the low wall thicknesses on prototypes for
later pressure die casting. And, with a directional
solidification in the sand casting mold, we fulfil
even the highest demands of our customers in
material properties and structure formation,
comparable to die casting. The mechanical
properties can be set precisely in the concluding
heat treatment.
Prototype Foundry
- aluminum, steel and iron alloys
- 5 induction aluminum furnaces with total 850 kg melting capacity
- 3 MFT-melting furnaces for iron and steel alloys with total 500 kg
capacity
- 850 kg melting capacity per hour
- spectrometer, vacuum density testing device, temperature indicator
- continous mixer with 5t/h up to 1,500 x 1,500 x 900 mm
pattern size
- core sand mixer AMF 60
- blasting cubicle for aluminum
- overhead monorail blasting unit HS 10/15 (2x 7.5 KW) up to
600 kg hook load
- 2 pressure blasting units
- compressed air-injector-blasting unit ST 1,400 PS
- conveyor system for furan sand
- 1,100 sqm production area
Heat treatment
- 2 circulating air - shaft furnace up to 850°C
- 2 circulating air - Chamber furnace up to 850 °C and up to 650 °C
- 3 chamber furnaces up to 1,200 °C
- 4 aging furnaces up to 300 °C
- 100 sqm production area
 Prototype Foundry
F o u n d r y
ACTech operates several melting furnaces for
aluminum, iron and steel alloys in its own foundry
center. This provides the flexibility to not only
realize up to 200 prototype projects at the same
time, but also to cast an assembled mold in less
than one hour. With the help of the vacuum-
P r o t o t y p e
supported casting technique, we are able to
achieve the low wall thicknesses on prototypes for
later pressure die casting. And, with a directional
solidification in the sand casting mold, we fulfil
even the highest demands of our customers in
material properties and structure formation,
comparable to die casting. The mechanical
properties can be set precisely in the concluding
heat treatment.
Prototype Foundry
- aluminum, steel and iron alloys
- 5 induction aluminum furnaces with total 850 kg melting capacity
- 3 MFT-melting furnaces for iron and steel alloys with total 500 kg
capacity
- 850 kg melting capacity per hour
- spectrometer, vacuum density testing device, temperature indicator
- continous mixer with 5t/h up to 1,500 x 1,500 x 900 mm
pattern size
- core sand mixer AMF 60
- blasting cubicle for aluminum
- overhead monorail blasting unit HS 10/15 (2x 7.5 KW) up to
600 kg hook load
- 2 pressure blasting units
- compressed air-injector-blasting unit ST 1,400 PS
- conveyor system for furan sand
- 1,100 sqm production area
Heat treatment
- 2 circulating air - shaft furnace up to 850°C
- 2 circulating air - Chamber furnace up to 850 °C and up to 650 °C
- 3 chamber furnaces up to 1,200 °C
- 4 aging furnaces up to 300 °C
- 100 sqm production area
 Raw Part Inspection
Raw Part Inspection
At ACTech all the equipment necessary for - X-ray analysis (unit with 160 kV)
- chemical analysis (spectrometer)
inspecting and checking the material properties - analysis of melting quality (vacuum density device)
and stucture are available. Starting in the - mechanical properties
hardness test
metallographic lab up to the fluoroscopy on the X- tensile strength
ray machine we are able to satisfy each customer - metallography
metallographic preparation
request. In addition, comparing the real raw part reflected-light microscopy
geometry against the 3D CAD dataset using the - measurement of wall thickness
ultrasonic measuring
optical scanning method is available as well. The magnetic-inductive measuring of wall thickness
best-fit adjustment enables the optimum CNC - crack detection
penetration inspection (dye, fluorescent)
machining in consideration of the lowest possible magnetic powder test
tolerances between raw part and machined part. - leakage test
- endoscopy (check for remaining sand)
- optical measurement at 2 GOM units
- offline-programming and analysis
- 160 sqm production area
I n s p e c t i o n
P a r t
R a w
 Raw Part Inspection
Raw Part Inspection
At ACTech all the equipment necessary for - X-ray analysis (unit with 160 kV)
- chemical analysis (spectrometer)
inspecting and checking the material properties - analysis of melting quality (vacuum density device)
and stucture are available. Starting in the - mechanical properties
hardness test
metallographic lab up to the fluoroscopy on the X- tensile strength
ray machine we are able to satisfy each customer - metallography
metallographic preparation
request. In addition, comparing the real raw part reflected-light microscopy
geometry against the 3D CAD dataset using the - measurement of wall thickness
ultrasonic measuring
optical scanning method is available as well. The magnetic-inductive measuring of wall thickness
best-fit adjustment enables the optimum CNC - crack detection
penetration inspection (dye, fluorescent)
machining in consideration of the lowest possible magnetic powder test
tolerances between raw part and machined part. - leakage test
- endoscopy (check for remaining sand)
- optical measurement at 2 GOM units
- offline-programming and analysis
- 160 sqm production area
I n s p e c t i o n
P a r t
R a w
 CNC Machining
Using 5-axis-simultaneous milling centers,
equipped with changeable table systems with
tables up to 1,250 mm in size and a 4-shift
operation, we are able to quickly produce
completely machined prototypes from raw castings
which are ready to be installed. CNC programming
with the 3D CAD dataset, machining simulations
and raw part alignment using the optical
measurement results ensure minimum scrap quota
and very short processing times.
The customer decides if he wants each part to be
subjected to a final 3D complete measurement, a
measuring of selected test dimensions or an in-
process measuring. ACTech has sufficient inhouse
capabilities available for all of these methods.
M a c h i n i n g
C N C
CNC Machining
- TEBIS programming system
- machining without any drawing available
- tool management system (Datos)
- alternating table system
- integrated tool pre-setting (Zoller) with scan function
- measuring during production process
- CNC milling/turning center:
1,250 x 1,000 mm maximum table size
10 5-axis simultaneous milling machines DMG
1 5-axis simultaneous milling machine HERMLE
1 3-axis simultaneous milling machine DMG
1 CNC turning center DMC
- 1,100 sqm production area
Machined Part Inspection
- 5 3D coordinate measuring machines
metering range: up to 1,200 x 2,200 x 1,000 mm
measuring accuracy: 1.7-2.5 µm according to metering range
offline-programming and analysis
- altimeter
- measuring tool for contour
- optical measurement at 2 GOM units with offline-programming
and analysis
- 250 sqm production area
 CNC Machining
Using 5-axis-simultaneous milling centers,
equipped with changeable table systems with
tables up to 1,250 mm in size and a 4-shift
operation, we are able to quickly produce
completely machined prototypes from raw castings
which are ready to be installed. CNC programming
with the 3D CAD dataset, machining simulations
and raw part alignment using the optical
measurement results ensure minimum scrap quota
and very short processing times.
The customer decides if he wants each part to be
subjected to a final 3D complete measurement, a
measuring of selected test dimensions or an in-
process measuring. ACTech has sufficient inhouse
capabilities available for all of these methods.
M a c h i n i n g
C N C
CNC Machining
- TEBIS programming system
- machining without any drawing available
- tool management system (Datos)
- alternating table system
- integrated tool pre-setting (Zoller) with scan function
- measuring during production process
- CNC milling/turning center:
1,250 x 1,000 mm maximum table size
10 5-axis simultaneous milling machines DMG
1 5-axis simultaneous milling machine HERMLE
1 3-axis simultaneous milling machine DMG
1 CNC turning center DMC
- 1,100 sqm production area
Machined Part Inspection
- 5 3D coordinate measuring machines
metering range: up to 1,200 x 2,200 x 1,000 mm
measuring accuracy: 1.7-2.5 µm according to metering range
offline-programming and analysis
- altimeter
- measuring tool for contour
- optical measurement at 2 GOM units with offline-programming
and analysis
- 250 sqm production area
 Intake module Crank case
Material: EN AC-AlSi8Cu3 Material: EN AC-AlSi8Cu3
Dimensions: 384 x 372 x 150 mm Dimensions: 384 x 372 x 150 mm

If the cylinder heads of a V-engine are connected
with an intake module, this module must be made
to a low tolerance. It is important to avoid a
misalignment of the channels and tensions
between the heads after assembling.
Minimized core shift and the use of modern
measuring methods during the mold assembly
ensured a wall thickness as low as 2mm.
Traditional tolerance stack and the resulting
machining stock had to be completely revised.

Intake module VR6 Cylinder head

with integrated exhaust collector
Material: EN AC-AlSi10Mg(Cu) Material: EN AC-AlSi7Mg0,3
Dimensions: 570 x 418 x 300 mm Dimensions: 510 x 360 x 340 mm

A low wall thickness and an excellent surface finish
were required for this intake module. Both
requirements were achieved by a special gating
system and a carefully applied coating for the sand
mold.
S a m p l e s
The integration of the exhaust collector into the
cylinder head allows the reduction of the number of
parts. The casting became somewhat more
challenging due to a more complex water jacket
that was required to guarantee proper cooling. The
reduced tolerance of the wall thickness was
maintained by using optical and tactile measuring
devices.
 Intake module Crank case
Material: EN AC-AlSi8Cu3 Material: EN AC-AlSi8Cu3
Dimensions: 384 x 372 x 150 mm Dimensions: 384 x 372 x 150 mm

If the cylinder heads of a V-engine are connected
with an intake module, this module must be made
to a low tolerance. It is important to avoid a
misalignment of the channels and tensions
between the heads after assembling.
Minimized core shift and the use of modern
measuring methods during the mold assembly
ensured a wall thickness as low as 2mm.
Traditional tolerance stack and the resulting
machining stock had to be completely revised.

Intake module VR6 Cylinder head

with integrated exhaust collector
Material: EN AC-AlSi10Mg(Cu) Material: EN AC-AlSi7Mg0,3
Dimensions: 570 x 418 x 300 mm Dimensions: 510 x 360 x 340 mm

A low wall thickness and an excellent surface finish
were required for this intake module. Both
requirements were achieved by a special gating
system and a carefully applied coating for the sand
mold.
S a m p l e s
The integration of the exhaust collector into the
cylinder head allows the reduction of the number of
parts. The casting became somewhat more
challenging due to a more complex water jacket
that was required to guarantee proper cooling. The
reduced tolerance of the wall thickness was
maintained by using optical and tactile measuring
devices.
 Compressor housing Exhaust manifold
with integrated Turbine housing
Material: EN AC-AlSi8Cu3 Material: EN-GJSA-XNiSiCr35-5-2
Dimensions: 154 x 132 x 73 mm Dimensions: 325 x 200 x 150 mm

Using optical measurement systems during mold
assembly and a second optical measurement of
the raw casting allows an adjustment in the
machining setup to contours which are not viable. A
compressor housing, where the exact location of
the inner scroll is critical to the function of the part,
is a good example of it.
The integration of additional functions to a casting allows
the reduction of parts. This results in highly complex
castings which are a special challenge for the machine
shop. To address this challenge, an optical measurement
of the raw casting is conducted and a CAD data
comparison is made to allow for best fit adjustments on
the CNC machine. These steps are necessary for
successfully machining such types of castings.

Turbine housing Turbine housing

Material: GX 40 CrNiSi 25 20 Material: GX 40 CrNiSi 25 20
Dimensions: 110 x 103 x 65 mm Dimensions: 146 x 146 x 103 mm

For small castings with very thin wall thicknesses, Thin walls in steel can be made by using vacuum
the correct placement of a core in the mold is pressure supported mold filling, a technology
essential. Supported by an advanced specially developed by ACTech.
measurement system, ACTech can achieve a very
low tolerance during mold assembly.
S a m p l e s
 Compressor housing Exhaust manifold
with integrated Turbine housing
Material: EN AC-AlSi8Cu3 Material: EN-GJSA-XNiSiCr35-5-2
Dimensions: 154 x 132 x 73 mm Dimensions: 325 x 200 x 150 mm

Using optical measurement systems during mold
assembly and a second optical measurement of
the raw casting allows an adjustment in the
machining setup to contours which are not viable. A
compressor housing, where the exact location of
the inner scroll is critical to the function of the part,
is a good example of it.
The integration of additional functions to a casting allows
the reduction of parts. This results in highly complex
castings which are a special challenge for the machine
shop. To address this challenge, an optical measurement
of the raw casting is conducted and a CAD data
comparison is made to allow for best fit adjustments on
the CNC machine. These steps are necessary for
successfully machining such types of castings.

Turbine housing Turbine housing

Material: GX 40 CrNiSi 25 20 Material: GX 40 CrNiSi 25 20
Dimensions: 110 x 103 x 65 mm Dimensions: 146 x 146 x 103 mm

For small castings with very thin wall thicknesses, Thin walls in steel can be made by using vacuum
the correct placement of a core in the mold is pressure supported mold filling, a technology
essential. Supported by an advanced specially developed by ACTech.
measurement system, ACTech can achieve a very
low tolerance during mold assembly.
S a m p l e s
 Rear axle transmission Coolant distribution
Material: EN AC-AlSi7Mg0,3 T6 Material: EN AC-AlSi7Mg0,3 T6
Dimensions: 332 x 318 x 237 mm Dimensions: 504 x 397 x 132 mm

Every ounce counts on the race track. Thin walled
castings in high strength aluminum alloys help
meet the requirements of light weight race car
components. Integrating additional functions to the
casting helps to reduce weight. These highly
complex casting solutions are a specialty of
ACTech.
In the past, rubber tubes were used to distribute
coolant. In modern cars and trucks, a casting often
does the job. In addition to higher reliability and a
longer life span, such castings can also perform
other functions within the unit. ACTech has
expertise in these types of highly complex
castings.

Crankshaft Converter housing

Material: EN-GJS-600-3 Material: EN AC-AlSi7Mg0,3 T6
Dimensions: 750 x 175 x 175 mm Dimensions: 370 x 365 x 70 mm

Not all crankshafts are forged. ACTech supplies
crankshaft prototypes in high strength iron alloys
which are comparable to production parts.
S a m p l e s
Hydraulic channels on both sides of the casting
require a high degree of accuracy during the mold
assembly. An additional challenge is the material
quality requirements. The casting must be tight and
the mechanical properties at the alloys limit in order
for the casting to perform successfully.
 Rear axle transmission Coolant distribution
Material: EN AC-AlSi7Mg0,3 T6 Material: EN AC-AlSi7Mg0,3 T6
Dimensions: 332 x 318 x 237 mm Dimensions: 504 x 397 x 132 mm

Every ounce counts on the race track. Thin walled
castings in high strength aluminum alloys help
meet the requirements of light weight race car
components. Integrating additional functions to the
casting helps to reduce weight. These highly
complex casting solutions are a specialty of
ACTech.
In the past, rubber tubes were used to distribute
coolant. In modern cars and trucks, a casting often
does the job. In addition to higher reliability and a
longer life span, such castings can also perform
other functions within the unit. ACTech has
expertise in these types of highly complex
castings.

Crankshaft Converter housing

Material: EN-GJS-600-3 Material: EN AC-AlSi7Mg0,3 T6
Dimensions: 750 x 175 x 175 mm Dimensions: 370 x 365 x 70 mm

Not all crankshafts are forged. ACTech supplies
crankshaft prototypes in high strength iron alloys
which are comparable to production parts.
S a m p l e s
Hydraulic channels on both sides of the casting
require a high degree of accuracy during the mold
assembly. An additional challenge is the material
quality requirements. The casting must be tight and
the mechanical properties at the alloys limit in order
for the casting to perform successfully.
 Compressor wheel Turbine inlet housing
Material: EN AC-AlSi8Cu3 Material: EN-GJS-400
Dimensions: 475 x 475 x 240 mm Dimensions: 1,200 x 1,200 x 550 mm

Tight tolerances and smooth surfaces are
production requirements for compressor wheels.
Usually this is achieved in an investment casting
process. ACTech offers an investment casting
process for prototypes that fulfills the same
demands at a fraction of the delivery time of
traditional processes.
For this turbine inlet housing tolerances of +/- 0,5 mm
were required. This is far below any applicable sand
casting tolerances. A special technology development
and use of advanced optical measurement systems
allowed us to achieve this ambitious goal.

Main gear housing (helicopter) Inlet case

Customer: ZF Luftfahrttechnik GmbH
Material: G-AlSi7Mg0.6 T6 Material: EN AC-AlSi7Mg0,6
Dimensions: 1,065 x 1,347 x 544 mm Dimensions: 520 x 520 x 350 mm

The standards required for the aerospace industry
go beyond what is required in other industries. An
additional challenge for the prototype foundry can
be if very large parts are needed. ACTech has
responded to the unique needs of the aerospace
industry since 2001.
S a m p l e s
In addition to the high demands of an aerospace
application, the inlet case holds a challenging inner
structure. In and close to the wall oil pipes are
integrated. Despite the low wall thickness, these
tubes have to withstand high pressure. Even small
deviations in the core location or small defects in
the casting would lead to a failure of the part.
 Compressor wheel Turbine inlet housing
Material: EN AC-AlSi8Cu3 Material: EN-GJS-400
Dimensions: 475 x 475 x 240 mm Dimensions: 1,200 x 1,200 x 550 mm

Tight tolerances and smooth surfaces are
production requirements for compressor wheels.
Usually this is achieved in an investment casting
process. ACTech offers an investment casting
process for prototypes that fulfills the same
demands at a fraction of the delivery time of
traditional processes.
For this turbine inlet housing tolerances of +/- 0,5 mm
were required. This is far below any applicable sand
casting tolerances. A special technology development
and use of advanced optical measurement systems
allowed us to achieve this ambitious goal.

Main gear housing (helicopter) Inlet case

Customer: ZF Luftfahrttechnik GmbH
Material: G-AlSi7Mg0.6 T6 Material: EN AC-AlSi7Mg0,6
Dimensions: 1,065 x 1,347 x 544 mm Dimensions: 520 x 520 x 350 mm

The standards required for the aerospace industry
go beyond what is required in other industries. An
additional challenge for the prototype foundry can
be if very large parts are needed. ACTech has
responded to the unique needs of the aerospace
industry since 2001.
S a m p l e s
In addition to the high demands of an aerospace
application, the inlet case holds a challenging inner
structure. In and close to the wall oil pipes are
integrated. Despite the low wall thickness, these
tubes have to withstand high pressure. Even small
deviations in the core location or small defects in
the casting would lead to a failure of the part.
 Steering wheel segments Hinged bracket housing
Material: EN AC-AlSi7Mg0,3 T6 Material: EN AC-AlSi7Mg
Dimensions: 363 x 229 x 150 mm Dimensions: 210 x 136 x 15 mm

In production, these parts will be die cast and can
be used without machining. Precision investment
castings from ACTech are an excellent substitute
for small quantity prototypes at a fraction of the
cost of a die.
Rather complex kinematics systems are part of
hinged brackets for tactile measuring systems. Due
to the nature of these systems, a high stability is
required. ACTech is not only providing prototypes
for such applications but also small quantity
production of these very special parts.

EGR tube Selector housing

Material: EN AC-AlSi10Mg T6 Material: EN AC-AlSi9Cu3
Dimensions: 495 x 160 x 135 mm Dimensions: 452 x 253 x 160 mm

Rapid prototyping technologies used for large
investment castings can produce excellent surface
finishes and precise dimensional accuracy.
Additionally, complex inner geometries can be
achieved with this technology.
S a m p l e s
Thin walls over large areas, complex ribs and very
low tolerances for warping made this casting an
interesting prototype. After the first prototypes,
ACTech did a small pre-production run while the tool
for the die casting was produced.
 Steering wheel segments Hinged bracket housing
Material: EN AC-AlSi7Mg0,3 T6 Material: EN AC-AlSi7Mg
Dimensions: 363 x 229 x 150 mm Dimensions: 210 x 136 x 15 mm

In production, these parts will be die cast and can
be used without machining. Precision investment
castings from ACTech are an excellent substitute
for small quantity prototypes at a fraction of the
cost of a die.
Rather complex kinematics systems are part of
hinged brackets for tactile measuring systems. Due
to the nature of these systems, a high stability is
required. ACTech is not only providing prototypes
for such applications but also small quantity
production of these very special parts.

EGR tube Selector housing

Material: EN AC-AlSi10Mg T6 Material: EN AC-AlSi9Cu3
Dimensions: 495 x 160 x 135 mm Dimensions: 452 x 253 x 160 mm

Rapid prototyping technologies used for large
investment castings can produce excellent surface
finishes and precise dimensional accuracy.
Additionally, complex inner geometries can be
achieved with this technology.
S a m p l e s
Thin walls over large areas, complex ribs and very
low tolerances for warping made this casting an
interesting prototype. After the first prototypes,
ACTech did a small pre-production run while the tool
for the die casting was produced.
 Good things take time ... 24 hours
Interested in receiving a quote?
All we need is the 3D CAD data set for the raw part
or machined part and the machining drawing. For
your planning purposes, we are also happy to provide
you with a quote even if your data has not yet been
finalized.
We also need to know the planned quantities, the
requested casting material, your in-house standards
and the quality requirements that apply. Based on
this information, we can establish an inspection and
test sequence and coordinate it with you.
If you already know what your needs will be like after
the first trial runs are complete, we should also
discuss the options available for reducing overall
costs. Why should you have to pay repeatedly for
services if you can keep using them right down to the
small series level?
S e r v i c e
CAD data that we can use:
- CATIA V5 ( *.CATPart )
- Pro/ENGINEER Part-files (.prt.n)
- Unigraphics (*.prt)
- Parasolid (*.x_t, *.x_b)
- STEP 214 (.stp)
- VDA-FS files (V2) (*.vda)
- IGES-files (*.igs)
For more Information about data transfer please
visit the service area at www.actech.de.
Confidentiality Certification
“Silence is the element in which The quality management system and environmental
great things fashion themselves together.” management system of ACTech GmbH are certified by
Thomas Carlyle (1795 - 1881) Det Norske Veritas (DNV) under ISO/TS 16949 and
philosopher, historian EN ISO 14001.
This certificate applies to the development and
production of casting prototypes and small batches,
including with CNC machining.
Naturally, confidentiality is very important to us. When
you entrust us with the results of your development work,
you can rest assured that your information is in good
hands. And, that it is securely stored, behind locked
doors. as work is always in progress on multiple projects
for various customers, site inspections of production
operations or even individual stages of production are
not permitted. It is, however, possible for us to meet with
you by appointment in a separate area to demonstrate
the production stages for your prototypes while they are
being produced.
, ACTech, CRONING, DIRECT CRONING, RAPID CASTINGS, DMM, DMM-Direct Mould Milling, Rapid Metal Technologies are registered trademarks from ACTech GmbH.
 Good things take time ... 24 hours
Interested in receiving a quote?
All we need is the 3D CAD data set for the raw part
or machined part and the machining drawing. For
your planning purposes, we are also happy to provide
you with a quote even if your data has not yet been
finalized.
We also need to know the planned quantities, the
requested casting material, your in-house standards
and the quality requirements that apply. Based on
this information, we can establish an inspection and
test sequence and coordinate it with you.
If you already know what your needs will be like after
the first trial runs are complete, we should also
discuss the options available for reducing overall
costs. Why should you have to pay repeatedly for
services if you can keep using them right down to the
small series level?
S e r v i c e
CAD data that we can use:
- CATIA V5 ( *.CATPart )
- Pro/ENGINEER Part-files (.prt.n)
- Unigraphics (*.prt)
- Parasolid (*.x_t, *.x_b)
- STEP 214 (.stp)
- VDA-FS files (V2) (*.vda)
- IGES-files (*.igs)
For more Information about data transfer please
visit the service area at www.actech.de.
Confidentiality Certification
“Silence is the element in which The quality management system and environmental
great things fashion themselves together.” management system of ACTech GmbH are certified by
Thomas Carlyle (1795 - 1881) Det Norske Veritas (DNV) under ISO/TS 16949 and
philosopher, historian EN ISO 14001.
This certificate applies to the development and
production of casting prototypes and small batches,
including with CNC machining.
Naturally, confidentiality is very important to us. When
you entrust us with the results of your development work,
you can rest assured that your information is in good
hands. And, that it is securely stored, behind locked
doors. as work is always in progress on multiple projects
for various customers, site inspections of production
operations or even individual stages of production are
not permitted. It is, however, possible for us to meet with
you by appointment in a separate area to demonstrate
the production stages for your prototypes while they are
being produced.
, ACTech, CRONING, DIRECT CRONING, RAPID CASTINGS, DMM, DMM-Direct Mould Milling, Rapid Metal Technologies are registered trademarks from ACTech GmbH.
Germany
K e e p o n e s t e p a h e a d .
ACTech GmbH
Halsbrücker Str. 51 R i g h t f r o m t h e s t a r t .
09599 Freiberg/Sa.
Germany
Phone: +49 3731 169 0
Fax: +49 3731 169 500
E-Mail: prototype@actech.de
www.actech.de

USA

ACTech North America Inc.

4343 Concourse Drive, Suite 350
Ann Arbor, MI, 48108
USA
Phone: +1 734 913 0091
Fax: +1 734 913 0095
E-Mail: info@rapidcastings.com
www.rapidcastings.com

India

ACTech GmbH Liaison Office

No 15/2, Sangama, Diagonal Road
Vasantnagar
Bangalore - 560 052
India
Phone: +91 80 41131342
Fax: +91 80 41131343
E-Mail: prototype@actech.in
www.actech.in

RAPID CASTINGS®

E n g l i s h v e r s i o n

www.actech.de