As the automotive industry evolves, MAPAL expects huge growth in the requirement for machining solutions for electric vehicles. The tool manufacturer has focused new product lines on components that will be made in large quantities in the future. The new Basic, Performance and Expert classification ranges describe customer-specific solutions for their machining needs.
MAPAL’s strong focus on customer needs when developing tool solutions is not a new concept. By arranging its options into three solution levels – Basic, Performance and Expert, the company now offers a classification for tool selection options for specific parts. In doing so, MAPAL now provides customers with a rough indication of product lines that will meet their needs, making the transition smoother in practice.
The Basic tooling systems include solutions with standard tools for manufacturing prototypes or small series products cost-effectively. The investment is comparatively low, and the use of tools is flexible. As many changes are often still being made to the component and process at this stage, the flexibility of the standard tool series is very helpful for manufacturers. Customisation tools is avoided in the Basic solution.
Performance solutions are designed for series production and focus on machining specific parts using custom tools. Here, multi-stage and combination tools can be used to process the workpiece more efficiently than with Basic versions. The Performance solution enables reliable series-ready production without fulfilling the very top tier of requirements for productivity. This is reserved for the Expert version.
The Expert line includes solutions for machining specific parts with the fewest tools possible productively in short cycle times with the best possible quality. Here, multi-staged tools that combine all functions in a single device are typically used. An example of an Expert solution is the toolset for machining the stator housing for an electric motor that MAPAL has already successfully established in the industry. MAPAL has taken productivity and quality to their absolute limits with these tools. Basic and Performance solutions are also available for manufacturing the stator housing, meeting the requirements for each level respectively.
Ambitious parts for electric cars
Alongside electric drives, MAPAL is also focusing on other electric car components. These include auxiliary units such as the scroll compressor for thermal management and housings for power electronics and battery frames. The latter requires many milling operations that can also be illustrated well with the three-staged Basic, Performance and Expert concepts. Comparatively simple standard tools can be used for tests or small quantities. The next level involves special solid carbide tools that combine several machining steps and ensure reliable machining. Furthermore, the Expert level brings milling cutters with special coatings or PCD milling cutters into play.
MAPAL determines the optimum solution for the relevant situation in direct dialogue with its customers. In many cases, customers will only take advantage of two of the three potential levels. This is because prototype production often takes place on specialist machinists. This is because OEMs want to transition straight from prototype to mass production. If the quality requirements are met and productivity is sufficient for the quantities to be manufactured, a Performance-level machining solution is used. Under certain circumstances, the demands placed on machine performance may not be quite as high with this solution, which can be a criteria choice when converting existing lines to e-mobility.
