The Fill Time Machine – tomorrow's foundry and machining technology

The Austrian company shows how high-tech mechanical engineering and digital tools can be combined to maximum effect.

The Fill innovation engine has been running at full speed for many years. The results of this fervent pioneering work will be presented at Euroguss 2024 in Nuremberg from January 16 to 18. High-speed machining of structural components with maximum precision can be seen on the exhibition stand in Hall 7A, stand 123. The innovative machining centers in the SYNCROMILL range and machining solutions for large-volume Gigacast and Megacast structural components herald a new era in the world of foundry and machining technology. With the ROBOCAST V vacuum metering system for low-oxide molten metal transport and precise mold filling, another highlight will be presented. The next key aspect is the digitalization of production plant and systems, which reaches a new level by means of CYBERNETICS applications. As a general contractor, the Upper Austrian machine engineering specialists combine a wealth of process expertise, covering everything from foundry operations to machining through to assembly technology.

"For us, innovation means being one step ahead at all times. Our engineers' passionate commitment to development leads to new solutions, while production and machining systems continuously enhanced and optimized. This generates a decisive competitive advantage for our customers. They can launch their products not only more quickly, but also more efficiently," explain Competence Center managers Friedrich Dallinger (Metal Machining Technology) and Thomas Rathner (Foundry Technology). Dallinger, Rathner, and their team are looking forward to many interesting discussions on the Fill exhibition stand at EUROGUSS 2024.

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ROBOCAST V

In the form of the newly developed ROBOCAST V vacuum metering system, Fill offers a highly productive casting process for innovative drive components and complex castings. It ensures maximum casting quality while reducing the amount of return scrap material. The casting system is used for low-oxide collection, manipulation, and pouring of molten aluminum, and ensures a consistently high casting quality thanks to constant, reproducible casting parameters. This delivery rate can be varied and adapted during the pouring process to comply with the requirements of the die. After pouring, the residual molten metal is handled in a protective atmosphere to prevent oxide formation in the system

ROBOCAST V

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SYNCROMILL C21-63/600 Y1200

SYNCROMILL C21-63/600 Y1200 – dynamic, reliable, efficient

Dynamism, reliability, and efficiency are the outstanding success criteria of the Fill SYNCROMILL C machining center. The flexible machine concept allows the widest variety of machining tasks to be performed with extremely short non-productive times. Thanks to the use of intelligent clamping solutions, workpieces are machined extremely economically and efficiently. With a 600 mm spindle spacing and 1,200 mm of Y-travel, the SYNCROMILL C21-63/600 Y1200 machining center has been developed above all for the profitable machining of elongated electronic casings made of die-cast metal and profiles. The interlinking with upstream or downstream processes can be adapted flexibly to meet individual customer requirements.

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GIGACAST – machining and automation of the future

The markets and, with them, the components are subject to constant change. This situation means that the machining and automation of Megacast and Gigacast die-cast parts is becoming one of the key challenges. Fill supplies the most efficient solutions for this dynamic process. With optimal clamping and tooling concepts and specifically tailored automation components, the SYNCROMILL machine tools are state of the art in this field. For best possible yield, Fill offers the use of highly flexible, driverless transport systems (FTS) as well as robot or portal solutions. Retooling and the implementation of future components are already taken into account in the system concept.

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CYBERNETICS ANALYZE

FILL CYBERNETICS – digital analyses in real time

The CYBERNETICS products are a key component of Fill’s machines and systems. They cover the entire bandwidth of required solutions – from the monitoring of complex individual operations and seamless component traceability, through to automated system optimization by means of artificial intelligence (AI). Not only standard solutions, but also customer-specific and platform-independent dashboards, provide an optimum overview and enable detailed analyses of production and machines. This enables consistently high availability levels and boosts productivity. The CYBERNETICS ANALYZE analysis platform is used to record and store all the relevant machine parameters of a SYNCROMILL system. With the help of edge computing and modern software architecture, the required evaluations and analyses can be activated and deactivated again at any time.

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Fill Service Platform – 24 hours a day

The Fill Service Platform is a highly professional tool for supporting the continuous workflow and ensuring high productivity. The digital service is offered around the clock. All the relevant information for all Fill systems, (service cases, documents, contacts, system documentation, and much more) can be called up via the platform. Service notifications can be viewed in real time and the whole service history is available.

Corporate data

Fill is a leading international machine engineering company based in Gurten, Upper Austria. With sophisticated high-tech systems and custom manufacturing solutions for metal, plastics and wood, Fill makes its customers the best in their fields. The automotive, aviation, sports and building industries all benefit from Fill’s expertise. Since it was founded in 1966, the company has distinguished itself through enormous innovative strength, strong values and the best jobs. “If you are seeking the best solution, shape your future with Fill” is the guiding principle of the company’s more than 1,000 employees. We are one!” is their vision and stands for togetherness not only with the team, but also with customers, suppliers and partners. The company is 100 percent family-owned and managed by Andreas Fill (CEO), Martin Reiter (CFO), Alois Wiesinger (CTO), and Günter Redhammer (COO). In 2023, Fill recorded sales of around 210 million euros.

Further information can be found at: www.fill.co.at