Quality components for motor sports success
With many years of experience and state-of-the-art CNC technology from DMG MORI, Kaiser Werkzeugbau is working as top supplier in motor sports
The success of a racing team in motor sports includes a reliable and accurately working supplier basis. Kaiser Werkzeugbau GmbH from Helferskirchen in Germany, established in 1984, has been active in this field for many years and knows the challenges it poses very well. Around 50 perfectly trained employees provide top quality and adherence to schedules based on their specialist know-how. In the past few years, the team has been continuously expanding its portfolio with complex mechanical components, which have been implemented since the season 2014 in the Porsche 919 Hybrid in the LMP1 class of the FIA World Endurance Championship (WEC). Kaiser Werkzeugbau meets the high standards of industrial processing with state-of-the-art manufacturing: 17 machining centers and turning machines from DMG MORI ensure process-reliable and flexible production.
“The more sophisticated a component is, the more it matches our range of services”, Thomas Kaiser, owner and Managing Director of Kaiser Werkzeugbau, states by providing an insight into his company’s corporate philosophy. Challenging assignments are a tradition here - ever since Kaiser Werkzeugbau accepted the first orders for motor sports at the end of the nineties. For a subcontractor like Kaiser Werkzeugbau, the implication is obvious: “The level of quality and degree of innovation are extremely high in this industry, so that we must keep pace from a manufacturing perspective as well in order to remain competitive”.
Complex geometries and sophisticated materials
In hindsight it can be said that Kaiser Werkzeugbau has continuously grown alongside the assignments of various racing teams. A tendency that is continuing, as Sales Manager Ragnar Bregler explains: “In Formula 1 we supply seven teams, placing highest demands on us, and the development in the field of rally sports and long-distance races is progressing visibly.” For two years, Kaiser Werkzeugbau has been manufacturing components for the Porsche 919 Hybrid, with which the racing team from Weissach has been starting in the LMP1 class of the FIA World Endurance Championship (WEC) since 2014. “Porsche is putting a lot of energy into this project and is counting on reliable suppliers”, Ragnar Bregler says with an optimistic view of the future.
As subcontractor for the Porsche team, Kaiser Werkzeugbau has proven itself not least with its long-standing experience in motor sports. The team is familiar with the short delivery times and required flexibility and knows the demand placed on quality inside out. After all, about 70 percent of the products are intended for the racing track. Adding to this are the repeat orders of components for automotive prototype construction. The other orders increasingly originate from the equally demanding aerospace engineering, for which the company has been certified since 2008. “Our core competency is complex geometries and sophisticated materials like titanium or nickel alloys. Motorsport customers as well as aircraft manufacturers benefit from this”, Ragnar Bregler confirms. Furthermore, the team can already contribute its expertise in the development phase and optimise constructions if required.
Innovative CNC technology for challenging motor racing components
As innovative as the target industries of Kaiser Werkzeugbau might be, production at the Helferskirchen site is equally state-of-the-art. The manufacturing expertise of the employees is realised in highly accurate components using advanced machine tool technology. A total of no less than 17 CNC machines are from DMG MORI. Regular investments in production guarantee machining quality and process reliability. More recent acquisitions include two turning machines of the CTX beta series and two DMU eVo machining centers. “Our range of machines is able to cover a broad portfolio of components”, says Ragnar Bregler. The component size ranges up to 800 mm.
With regard to the Porsche 919 Hybrid, Kaiser Werkzeugbau manufactures a large variety of mechanical components. “From the disc bell and components for steering and the engines up to structural parts, we can build almost all essential components of a racing car”, Ragnar Bregler says. Due to the high complexity, the focus is on productive manufacturing solutions like 5-axis technology. “The fewer setups are required, the more efficient and above all precise our work can be.” Tolerances in the µm range and smooth surfaces prevail here. Kaiser Werkzeugbau remains faithful to the high standards of industrial processing for future machine acquisitions as well. With an HSC 70 linear, Thomas Kaiser intends to expand the capacities in the near future: “High-speed milling is predestined for high surface qualities”. Kaiser Werkzeugbau is going to continue its productivity with the machining center also in the field of gear milling.
Over the years, Kaiser Werkzeugbau has achieved the status of top supplier in motor sports with its innovative and quality-orientated manufacturing. Partnerships with various racing teams play a major part in the motivation to maintain this level according to Ragnar Begler: “With our products, we always share the success on the racetrack to some degree - naturally we also join in the excitement at events”.
In DMG MORI the racing team has found a partner, which as innovation leader in the field of machine tool manufacturing can contribute to its success in motor sport. DMG MORI supports Porsche in two ways: First, as a long-time supplier for companies that make high-quality vehicle components for the team. Second in the course of the season 2014 a dedicated component production department has been set up at DECKEL MAHO Seebach that supplies Porsche with a growing range of vehicle components. The specially installed „Porsche Motorsport CNC Competence Center“ stands for precision, flexibility and the transfer of innovative technologies. After all the ultimate aim is to develop intelligent manufacturing solutions for demanding parts. Whereby the focus is explicitly on the long-term transfer of technology as the key cornerstone of sustainable success.