- 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.
If required, we also take over the prototype phase and perform static, life and vibration tests in our own development laboratory. In addition to strength and life tests, metallographic analyses and professional cleanliness tests are also available.
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
- 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 Co’s own use. Appr. 95% 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.
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 five 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
Our machining operations are continuously developing. In response to increasing customer requirements in recent years, we are steadily expanding our vertical integration. More complex casting geometries and rising quality standards also make the continuous advancement of our production equipment and technologies essential.
Our service portfolio ranges from surface treatment (e.g. blasting and vibratory finishing) to precision machining, assembly, and various testing and welding processes. Today, the production of high-cleanliness cast components is possible at our Budapest – Csepel and Dunavarsány sites. In addition, FÉMALK is nowadays one of the leading suppliers of flanged cast components in Europe.
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:
- Milling
- Drilling
- Thread cutting
- Thread forming
- Turning
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:
- press-fitting threaded steel inserts
- flanging
- assembly of Helicoil inserts
- installation of rubber inserts
- MIG–MAG welding of cross members
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.
Our machine park includes large-capacity vibratory finishing systems, linear blasting systems, as well as overhead conveyor blasting systems for larger components.
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!
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