- OUR ACTIVITIES
WHAT DO WE DO?
Research & Development
The Research & Development area participates in R&D projects, working together with the development departments of automobile manufacturers, where our task is to develop mass-optimised castings that meet the construction space and requirements list received from the customer, while meeting various kinematic and mechanical boundary conditions, so that the subsequent quality and efficient serial production of the products is maintained.
During our simulations, we use our own, internally validated material curves and failure characteristics, which allow us to perform very accurate calculations regarding the behaviour of the final part.
We conduct the prototype phase according to customer requirements, and perform static, life, vibration and other tests of the products, for which we have our own development lab available. In addition to strength and service life tests, it is also possible to evaluate metallographic cuts and professionally perform cleanliness tests.
Our CAD software:
- CATIA
- CREO
- NX
Our CAE software:
- ANSYS
- ALTAIR Hyperwoks
- CATIA GPS/GAS
- Ls-Dyna
- nCode
Development lab tools:
- INSTRON tensile machines 250kN
- IST pulsator 27kN and 65kN, even for two-component tests
- OLYMPUS microscopes
- SPEKTROLAB spectrometer
- HYDAC type washing equipment in a clean room
- 2 pcs 3D printers (SLA, FDM)
For vibration and natural frequency tests, our engineers have acceleration sensors, an impulse hammer and the necessary amplifiers and signal processing systems at their disposal.
Our relations with universities and research institutes:
Budapest University of Technology and Economics, Faculty of Mechanical Engineering
University of Miskolc, Faculty of Materials Science
Bay Zoltán Nonprofit Ltd. (BAY-ATI), (BAY-LOGI)
István Széchenyi University
Österreichisches Giesserei-Institut (ÖGI)
Our company has a tool manufacturing plant with a highly qualified team of nearly 100 people, which manufactures tools exclusively for FÉMALK Zrt.’s own use. Appr. 85% of the tools ordered are made here, guaranteeing consistent quality and short lead times.
We are constantly expanding and modernizing our machinery fleet in line with growing customer needs. High-quality and precise production is ensured by block and wire EDM machines, as well as modern 3- and 5-axis CNC machining centres.
Thanks to our own design team, we ensure extremely short design times. Tool design engineers work in close collaboration with foundry technology specialists and R&D engineers to create the most optimal tool design for a given task.
During the design, we use MAGMA simulation software, which allows us to optimise the mould-filling process. At critical points, we even apply the most modern solutions, such as Jet Cooling, Squeeze Pin, shape-following cooling or vacuum forming.
We are proud to be the official development partner of the software development company MAGMA, so we can apply the latest technological developments first-hand.
Our CAD/CAM software:
- Creo
- PowerSHAPE
- PowerMILL
- MAGMASOFT
The main activity of FÉMALK Zrt. is aluminium die casting, which is a special branch of foundry. In this process, molten aluminium is injected at high speed into a reusable, often complexly designed, steel mould with moving cores using a ram. This technology allows the economical and rapid production of products of great complexity and excellent dimensional stability.
Our parts weigh between 30 and 5,000 grams and are manufactured in fully automated casting cells of 400–1,850 tons. Our production capacity in Dunavarsány will continue to expand from October 2025: we will serve our customers with new casting machines of up to 3,500 tons. 100% of our casting machines are so-called casting cells, where the casting process is fully automated. This allows machine operators to perform other tasks at the same time and spend more time on product quality control. The casting cells are also equipped with systems for monitoring and recording casting parameters, which further increases production reliability and the quality of the final products.
We deliver more than 50 million parts annually, for which we have an annual melting capacity of more than 40,000 tons. We are currently prepared to process six different base alloys:
- EN AB-46000 (AlSi9Cu3(Fe))
- EN AB-44300 (AlSi12(Fe))
- EN AB-47100 (AlSi12Cu1(Fe))
- EN AB-42400 (AlSi7MnMg)
- EN AB-43500 (AlSi10MnMg)
Moreover, we are able to handle special customer needs.
Our product portfolio is primarily designed for automotive applications, including:
- suspension parts
- engine and transmission mounts
- electronics cover structures
- air conditioning compressor units
- luminaire covers
- thermostat housings
- chassis elements
In response to the constantly expanding customer demands, the metalworking department of FÉMALK Zrt. performs more and more technological operations up to the production of the finished product. More complex casting geometries and stricter quality requirements require the constant development of our production equipment and technological capacities.
Our services range from surface treatment (e.g. shot blasting, grinding) to high-precision machining and assembly, to various inspection and welding procedures. High-purity casting production can also be carried out at both sites. FÉMALK has now become one of Europe’s leading suppliers of flanged castings.
Heat treatment capacity
We offer our customers a wide range of heat treatment options, including O, T5, and high-temperature solution heat treatments (T4, T6, T7). These enable targeted optimization of the mechanical properties of the parts.
Our metalworking activities
Our main operations:
- Pressing threaded steel elements
- Flanging
- Deburring (abrasion, grit blasting)
- CNC machining (milling, drilling, tapping, thread forming, turning)
- Installing Helicoil-inserts
- Heat treatment
Cutting solutions
We perform cutting with custom-made devices and chucks, and optimise machining processes using custom-made tools. The accuracy of manufactured parts and the presence of operations are frequently checked with dedicated inspection equipment to ensure the highest level of quality.
Assembly and flanging
The proportion of fully assembled castings is increasing, so we are constantly expanding our assembly competence. Our common operations include:
- pressing steel elements
- flanging
- installation of rubber pads and thread reinforcement elements
For process safety, we use Poka Yoke control gates in several operations to help prevent errors and ensure ongoing compliance.
Surface treatment
We perform surface treatment operations in accordance with customer expectations, such as:
- deburring
- abrasion
- grit blasting
Our equipment includes high-capacity linear blasters and abrasives, as well as hook-type machines, which are suitable for handling larger parts.
Prototyping and development
FÉMALK is also a reliable partner in product development. Our cutting department is actively involved in the development of various automotive and motorcycle components. We work closely with the product development department to produce prototypes until the part reaches its final shape and manufacturability optimisation.
- CAREER
Join the FÉMALK team!
Be part of a true Hungarian success story! Join us and build your future in a stable, innovative and family-friendly environment. We are waiting for you, whether you are a beginner or an experienced professional!
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