Magnesium and aluminium casting, machining, forged parts and anodes – development through to series production from a single source
Gerpolux Cooperation GmbH
54655 Malbergweich (DE) · Krakow (PL) · Sainte-Gauburge-Sainte-Colombe (FR)New on Amplifa
About Gerpolux
Gerpolux Cooperation GmbH, based in Malbergweich (Eifel), realises customer-specific products from development through prototypes and pre-series to series production. The portfolio covers magnesium and aluminium casting (sand casting and gravity die casting) with unit weights of over 200 kg, CNC milling with up to 5 simultaneous axes, CNC turning, deep hole drilling, welded constructions in magnesium and aluminium as well as forged parts in brass, copper and aluminium. Own product lines include anodes for cathodic corrosion protection, forged and tinned battery terminals, head expanders and accessories for vibration technology as well as rubber parts and plastic injection moulding. In addition, we offer pattern making, re-engineering of spare parts, procurement services and assembly. Customers come from aviation, automotive and military vehicle construction, mechanical engineering, agricultural machinery technology as well as from water utilities and energy suppliers. Offices in Germany, Poland and France ensure support across Europe.
- Site
- Malbergweich
- Processes
- Magnesium sand casting / gravity die casting, Aluminium sand casting / gravity die casting, Aluminium die casting incl. mechanical machining (partner India), CNC milling with up to 5 simultaneous axes, CNC turning, Full milling, Deep hole drilling, Welding technology for magnesium and aluminium (cast-welded constructions)
- Materials
- Magnesium AZ91, Magnesium AZ63, Magnesium RZ5, Magnesium M60, Magnesium MRI, Magnesium special alloys, Aluminium (common alloys), Brass
- Industries
- Aviation and aerospace, Automotive industry, Mechanical engineering, Spare parts industry, Military vehicle construction, Commercial vehicle technology
- 01
Development / Design
- 02
Pattern making
- 03
Sand casting / Gravity die casting / Die casting / Forging
- 04
Heat treatment
- 05
CNC machining (milling, turning, deep hole drilling)
- 06
Welding
- 07
Coating
- 08
Assembly
- 09
Quality control and delivery
Materials and Processes
Magnesium AZ91
Standard alloy for magnesium sand casting with high castability.
Magnesium AZ63
Proven casting alloy, among other things for anodes and cast parts.
Magnesium RZ5
Casting alloy for demanding sand cast components.
Magnesium M60
Magnesium alloy for sand cast products.
Magnesium MRI
Magnesium alloy for highly stressed cast parts.
Magnesium special alloys
Special alloys to customer specification.
Aluminium
Common alloys for sand casting, gravity die casting and die casting.
Brass
Hot-pressed forged parts such as battery terminals.
Copper
Forged parts produced with shaped tools.
Zinc
Material for anodes in cathodic corrosion protection.
Steel
Material for machining, dies and special materials.
Plastic and rubber
Injection-moulded parts and rubber parts to standard or customer specification.
Sites
Malbergweich
DEHeadquarters, development and sales
- Materials
- Magnesium, aluminium, brass, copper, steel, plastic
- CNC milling machines with up to 5 simultaneous axes
Krakow
PLOffice, representation and pattern making
- Materials
- Wood, plastic, steel (patterns/dies)
Sainte-Gauburge-Sainte-Colombe
FROffice, representation and consulting
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Magnesium sand casting / gravity die castingCasting | – | – | 200 kg and more | – | Magnesium AZ91, Magnesium AZ63, Magnesium RZ5, Magnesium M60, Magnesium MRI, Magnesium special alloys |
| Aluminium sand casting / gravity die castingCasting | – | – | – | – | Aluminium, Aluminium alloys (common) |
| Aluminium die casting incl. mechanical machining (partner India)Casting | – | – | – | – | Aluminium |
| CNC milling with up to 5 simultaneous axesMachining | – | – | – | Single piece / prototype – continuous medium series | Various materials, Light metals, Steel, Special materials |
| CNC turningMachining | – | – | – | Single piece – continuous medium series | Various materials |
| Full millingMachining | – | – | – | – | – |
| Deep hole drillingMachining | – | – | – | – | Light metals, Steel, Special materials |
| Welding technology for magnesium and aluminium (cast-welded constructions)Joining | – | – | – | – | Magnesium, Aluminium |
| Forging of brass, copper and aluminium (die forging, incl. die procurement)Forming | – | – | – | – | Brass, Copper, Aluminium |
| Warm presses of brass (hot-pressed brass parts)Forming | – | – | – | – | Brass |
| Coating processes: corrosion protection, painting, powder coatingSurface | – | – | – | – | – |
| Tinning (battery terminals)Surface | – | – | – | – | Brass |
| Assembly of parts and assemblies (outsourcing)Assembly | – | – | – | – | – |
| Cable assemblyAssembly | – | – | – | – | – |
| Mechatronic assembliesAssembly | – | – | – | – | – |
| Head expanders, sliding plates, couplings, clamping cubes for vibration technology (ready forCasting | – | – | 450 kg – 500 kg | – | Magnesium, Aluminium |
| Pattern making (casting patterns in wood, plastic; dies in steel; repair/conversion of old patterns)Engineering | – | – | – | – | Wood, Plastic, Steel |
| Prototypes, pre-series and small series up to series product (development from a single source)Engineering | – | – | – | – | – |
| Heat treatment (after sand casting)Heat treatment | – | – | – | – | Magnesium, Aluminium |
| Plastic injection moulding (standard and custom)Plastic | – | – | – | – | Plastic, Rubber |
| Rubber partsPlastic | – | – | – | – | Rubber |
2 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| CNC milling machines (up to 5-axis simultaneous) | – | – | – | – | Germany/France/Poland (partner network) |
| Injection moulding machines (plastic) | – | – | – | – | – |
Additional services
History
- 1930
EIFELWERK manufactures anode products in Germany, whose customers Gerpolux supplies today
- 2021
Publication of the website gerpolux.de (September 2021)