Space-Saving Machining of Large Parts

In the tool and mold making industry, companies integrate advanced multi-axis machining centers and automated turning-milling solutions to handle large, complex workpieces while maximizing efficiency within limited production space.

Activity and operational challenges
Founded in 1969 in Micheldorf, Austria, ifw mould tec GmbH develops and manufactures technically sophisticated injection molds for plastic pipe fittings, specializing in large-scale mold making for systems with diameters up to ø 1,500 mm. With approximately 140 employees, the company serves customers worldwide across Europe, the Americas, and Asia. A unique strength of the corporate group is its close tie to sister company ifw kunststofftechnik, which handles mass production, pilot runs, and small batches to ensure a seamless transition from tooling to full-scale production. However, the industry-wide trend toward larger and more complex molds pushed the company's existing production capacity to its limits, resulting in capacity bottlenecks and limited shop floor space.

Improvement objectives
The primary goals were to overcome capacity bottlenecks in machining large workpieces, reduce lead and setup times, and maximize productivity within a constrained factory layout. The company also sought to enhance process reliability, build greater manufacturing flexibility, and future-proof operations against increasing global price pressure through digitalization and automation initiatives.

Selected technical solution
To address these challenges, ifw mould tec GmbH invested in a DMG MORI DMU 210 P for 5-axis machining of large molds. In 2025, the machining infrastructure was further expanded with the installation of a CTX beta 450 TC equipped with Robo2Go automation, a DMU 95 monoBLOCK, and a DMV 60 dedicated to the training workshop. Production processes are supported by standardized CAM programming utilizing hyperMILL alongside connected DMG MORI technologies for a digitalized manufacturing environment.

Deployment and support
The long-term, trust-based partnership between ifw mould tec GmbH and DMG MORI facilitated the systematic integration of these high-tech machines into existing workflows. The collaborative relationship ensures continuous process optimization and reliable day-to-day operations across the tooling and production lines.

Quantifiable results and operational benefits
The investment delivers significant operational advantages, including increased productivity through complete machining and automation, reduced setup and lead times, and space-saving machining of large workpieces. The seamless integration of these technologies enhances manufacturing flexibility and process reliability, while automation initiatives enable unattended manufacturing and future-proof production. As emphasized by the company, "Our collaboration with DMG MORI is a long-term, trust-based partnership that helps us continuously optimize our processes. DMG MORI continues to impress us both technologically and in day-to-day operations."

Edited by Maria Brueva, Induportals editor – adapted by AI.

www.dmgmori.com