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Being able to accept orders quickly while remaining flexible is a crucial factor in making A. Erglis GmbH competitive. To achieve this, the model making and mold construction company relies on Zimmermann portal milling machines, and has done so for more than 28 years. The machine fleet continues to grow with the capacities of orders and was recently complemented by a compact FZU22. A. Erglis is using this system, which is reduced to its essentials, exclusively for processing composites and plastic parts.

"What makes us so competitive? We are able to react very swiftly when it comes to client orders and are thus able to deliver quickly-a crucial factor for our clients, especially those in the motorsports sector," said Rainer Eckelt, Executive Manager of A. Erglis GmbH in Heilbronn, Germany.

The company, specializing in model making and mold construction, was founded in 1965 by Arnold Erglis. It was taken over by Josef Eckelt in 1979, who then passed on the company to his son Rainer in 2003. The team, consisting of over 30 employees, constructs molds, models and prototypes according to client specifications and requirements. Following this process, specialists program the data for the NC milling machines.

"Because we are offering construction as well as manufacturing from one single provider, we guarantee flawless compatibility," said Eckelt. The materials used are epoxy resin, Ureol, various plastics, aluminum and steel, among others.

Besides motorsports, other clients are primarily operating in the automotive and aerospace sectors.

"Often, we receive an order on Monday, asking for delivery on Friday," said Eckert. "This can be positive molds, but also direct machining tools for the sidepods or the front spoiler of a car." Eckelt usually declares these especially urgent projects a top priority for himself. "If I open an e-mail in the evening, it is almost always difficult to catch any sleep at night. After all, the client does not want to fall behind on race day. Not a lot of suppliers offer such service." To ensure this kind of speed, the company also relies on its network, which is able to quickly supply the needed materials in the necessary quantity.

It is All About the Workspaces

Every order is different. There can be parts with complex shapes, but also simple parts, unique parts or parts demanded at large quantity-and the size also varies significantly.

"We are, for example, able to manufacture small components economically by using large machines with interchangeable plates, whereas we would not be able to manufacture large components on small machines," said Eckelt. Due to this, the machine fleet has adapted to the order situation in recent years. The major share of systems is produced by Zimmermann. "We already knew about the company from model construction. In 1997 we got the first portal milling machine-a FZ30," Eckelt said. Back then, he was already working in the family business, while his father was still leading the company. "We liked the regional proximity, because fast service is a very important factor," he said. "In addition, we quickly established a relationship of mutual trust with Rudolf Gänzle, the Director and Executive Manager at F. Zimmermann GmbH in Germany at the time. The contract was not signed, but sealed by a handshake, as usual in this time."

For the first portal system, the company built a new hall, which continued to fill up. Since the FZ30 was not designed for aluminum, but rather for plastics, a FZ37 was added in 2002 and another one of the same model four years later. Afterward, Zimmerman exchanged the first FZ30 with a new one, providing larger workspaces. A FZ33 compact followed, allowing quick and complete processing of aluminum and composite parts from all five sides-furthermore, it enables the company to finish steel and cast components with high dynamics and in simultaneous operation. Two machines from Zimmerman are also running during the two-shift operation of the company.

"We always selected the systems by the size of their workspaces and the technologies, which are continuously developed further by Zimmermann," Eckelt said. "Of importance are short processing times and high precision to avoid reworking the components, as well as high availability of the systems."

Efficiently Plastic Milling

Last year, Rainer Eckelt expanded the machine fleet again. "We spent one or two years searching for an economical portal system that we can exclusively use for composites and plastics, while not having to invest more than a million."

The FZ30 with interchangeable plate system had become too slow for him in the meantime, due to its set-up times paired with the multitude of components. Alongside factors like reliability and efficiency, the price played a particularly important role. He looked at different machines, including those from competitors. Of course, there had been discussions with Zimmermann and with Rudolf Gänzle, who is still closely connected to A. Erglis GmbH.

The initial plan included a FZU32. The compact 5-axis portal milling machine specifically processes aluminum, but also fiber-reinforced composites, plastics and Ureol. The centrally guided portal is rigid and less vulnerable in adverse environmental conditions due to the thermo-symmetrical design.

"We liked the machine, but it was too much for our limited demands, including the price," said Eckelt.

But Gänzle did not give up. Eckelt was then able to take a look at a FZU22 at another model making and mold construction company, and saw that "it is basically a base, or economy version of its bigger sister machine," described Sandra Bayer Teixeira, Marketing Manager at Zimmermann Germany. "We were also able to talk to the operator and even mill a test part." The result was compelling due to its high precision and the quality of its surface finish.

It became clear to Eckelt that this was the right decision. The construction space measures 1,800 mm x 3,000 mm x 1,250 mm. The standard equipment includes, among other things, a 12- or 24-position tool changer. The specifically developed, dynamic 5-axis milling head C2 with fork head and the 15 kW spindle is suited even for hard-to-reach areas due to its geometry. It is equipped with a two-sided bearing pivot axis, which is made of cast iron.

Adapted to Specific Requirements

Eckert was able to customize the machine. This way, the FZU22 was equipped, for example, with a double-acting zero-point clamping system, so it could have two interchangeable plates installed at the same time. The dust extraction was manufactured independently, while the air-conditioned hall is sufficient for cooling.

"We refrained from using anything we do not need, which makes the machine even more efficient," said Eckert.

Easy Transport, Easy Installation

"The nice part about such a compact system: transportation is quite uncomplicated," said Teixeira. "It took only a few months for the machine to be built and delivered. We did not have to disassemble our lightweight machine when loading it on a truck and a crane was able to lift it into the hall. The tools for the FZU arrived soon after."

Eckelt said: "We are satisfied, and also surprised, by how fast the minimally equipped machine was able to complete the first orders-many small parts made of plastic-within one clamping process."

For more information contact:

Zimmermann Inc.

30587 Century Drive

Wixom, MI 48393

248-956-8511

sales@zimmermann-inc.com

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