Before the start of tool production, an accurate and detailed design is required. Most of our customers require construction planning. If the customer has his own design, it is possible to import it, work on it and tailor it to tool production. Our construction tools automatically write programs for our machines that enable us to produce complex tools very precisely.
As part of our service and product design, we offer our customers competent analysis for ideal materials, finishing, prediction and elimination of potential problems. For the production of tools we use the latest technological achievements, which enable higher precision and quality of tool production. A 24-hour work schedule in three shifts ensures on-time completion.
The production of tools from plastic and cast parts of the highest quality and precision is the heart of our factory. All our CNC machines are connected to CAD/CAM workstations. The tools are modelled three-dimensionally with modern CAD/CAM systems, so that we can develop 3D data about the 3D structures that control the entire chain of CNC machining - right up to the final phase. In three related toolmaking areas, engineering and production manufacture top industrial tools of varying size and complexity, making us one of the best tool houses in Europe. There is hardly a large manufacturer in the automotive industry who does not use at least a few tools from EMKA mould making.
The combination of knowledge, experience and exceptional creativity in tool design has earned our company recognition from many manufacturers of plastic products. Without excellent tools there can be no excellent products. The tools from EMKA mould making always offer more than just one solution.
If the partner/customer has an idea and needs a professionally developed design, our designers can meet their needs with 3D CAD software. With elaborated designs, partners/customers can save resources and time during the production process and improve the quality of their products. Thanks to the precision of our CNC milling machines, we use fewer eroding machines today. However, the high demands on precision sometimes require the use of eroding machines - often in situations where we cannot access the surface of the plate with milling machines.
Erosion (Electrical Discharge Machining) is a processing method that is ideally suited for heavy metals, small, complicated shapes or, above all, materials that require sharp edges. It is a method of removing batches of material with electrical charges (sparks) between the electrode and the worktop. With precise paths defined by software electrodes, it flows into the material and processes it contactlessly. Emitted sparks remove material from the worktops.
Our eroding machines are able to work with a tolerance of 0.003 at high speed and reliability. These machines offer the best quality currently available with copper and graphite electrodes. The 3R modular system allows more electrodes to be used, allowing higher accuracy and repeatability in a single mode.
- The dimensions of the largest tool we manufacture are 1500x1000x900x900.
- Annual production is 900 tools.
- Most of our machines are used for the production of large tools.
EMKA mould making works with 86 different machine types:
- 28 high-speed CNC machines. Most of them come from world-class manufacturers such as Makino, Mirkon, Okuma, Deckel Maho, Hermle, Mitsubishi, Micron, Ingersol,
- 20 eroding machines. The majority of them come from the German manufacturer Ingersol, the rest from the Japanese Makino,
- 6 HSP machines for the production of graphite electrodes,
- 5 machines for cutting metal with wire,
- 4 grinding machines,
- 10 drilling machines,
- 8 manual lathes,
- 5 CNC lathes, 2 with 5 axes.