Die-cast parts in aluminium, magnesium and zinc – from engineering through casting and CNC machining to assembly
POWER-CAST (Kopf Holding GmbH)
Kirchheim/Teck (Holding) · Velbert · Enger · Stockheim · Neukirch/Lausitz · Schlierbach · Ortmann (CZ) · Monterrey (MX)New on Amplifa
About POWER-CAST
The POWER-CAST group unites several long-established die-casting foundries under the umbrella of Kopf Holding GmbH, based in Kirchheim/Teck. The mid-sized, family-owned company produces die-cast parts in aluminium, magnesium and zinc and is represented with locations in Germany, the Czech Republic and Mexico. Its service portfolio covers the entire value chain: engineering, prototypes and mould-filling simulation, toolmaking, casting, deburring, CNC machining, plastic overmoulding, surface finishing, as well as assembly and logistics – as a full-service supplier through to fully assembled components. The focus is on the cold chamber die-casting process; customers come predominantly from the automotive sector, including Siemens AG as an outstanding customer. With the zinc alloy Low-Carbon Z410, produced using zinc made with renewable energy, the group also offers a way to integrate low-carbon material into the supply chain.
- Site
- Kirchheim/Teck
- Processes
- Aluminium die casting, Magnesium die casting, Zinc die casting, Cold chamber die casting, FGS technology (Frech Gating System) in zinc die casting, Engineering, Prototype creation, Mould-filling simulation
- Materials
- Aluminium, Magnesium, Zinc, Low-Carbon Z410 (zinc alloy with low-carbon zinc), Plastic, Aluminium die casting, Magnesium die casting, Zinc die casting
- Certificates
- DIN EN ISO 9001, ISO/TS 16949 or IATF 16949, DIN EN ISO 14001, DIN EN ISO 50001, IATF 16949 (Magnetech), ISO 9001, IATF 16949, ISO 14001, ISO 50001
- Industries
- Automotive
- 01
Engineering
- 02
Prototype creation
- 03
Mould-filling simulation
- 04
Toolmaking
- 05
Casting
- 06
Deburring
- 07
Machining
- 08
Plastic overmoulding
- 09
Surface treatment and finishing
- 10
Assembly
- 11
Logistics concepts
Materials and Processes
Aluminium die casting
Construction and structural parts for automotive, e-mobility and electrical applications, at the Vobra site with part weights from 50 to 5,000 g
Magnesium die casting
Lightweight, high-strength interior and structural components in cold chamber die casting, at Zitzmann since 1992
Zinc die casting
Complex precision parts, also as a substitution for gravity die casting, with an innovative FGS gating system in series production
Low-Carbon Z410 (zinc alloy)
Zinc alloy with low-carbon zinc from renewable energy, for a CO2-reduced supply chain
Plastic
Plastic overmoulding for fully assembled components
Locations
POWER-CAST Ortmann, Velbert
DEZinc die casting
- Materials
- Zinc
- FGS technology (Frech Gating System)
POWER-CAST Vobra, Enger
DEAluminium die casting, approx. 1,300 t/year
- Part weight / size
- Part weights 50 – 5,000 g
- Lot size
- small to medium series
- Materials
- Aluminium
- CNC turning and machining centres with Fanuc control
- automated die casting machines with robotic part removal
POWER-CAST Zitzmann, Stockheim
DEMagnesium die casting since 1992
- Materials
- Magnesium
- Cold chamber die casting machine with 1,650 t clamping force (fully automated casting cell)
- Robots for part removal and handling
POWER-CAST Magnetech, Neukirch/Lausitz
DEMagnesium die casting
- Materials
- Magnesium
POWER-CAST Light Metal Solutions, Schlierbach
DELight-metal die casting
- Materials
- Aluminium, Magnesium
POWER-CAST Ortmann (Czech Republic)
CZDie casting
- Materials
- Zinc
POWER-CAST Monterrey
MXDie casting
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Aluminium die castingCasting | – | – | – | – | Aluminium |
| Magnesium die castingCasting | – | – | – | – | Magnesium |
| Zinc die castingCasting | – | – | – | – | Zinc |
| Cold chamber die castingCasting | – | – | – | – | Magnesium, Aluminium |
| FGS technology (Frech Gating System) in zinc die castingCasting | – | – | – | – | Zinc |
| EngineeringEngineering | – | – | – | – | – |
| Prototype creationEngineering | – | – | – | – | – |
| Mould-filling simulationEngineering | – | – | – | – | – |
| Toolmaking (casting tools)Engineering | – | – | – | – | – |
| DeburringSurface | – | – | – | – | – |
| Machining (CNC cutting, turning and machining centres, thread cutting)Cutting | – | – | – | – | Aluminium, Magnesium, Zinc |
| Plastic overmouldingPlastics | – | – | – | – | Plastic |
| Surface treatment and finishingSurface | – | – | – | – | – |
| Assembly and logistics concepts (fully assembled components)Assembly | – | – | – | – | – |
| Quality inspection (3-D measuring machines, X-ray inspection, spectral analysis, leak testing,Testing | – | – | – | – | Metal, Plastic |
4 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Cold chamber die casting machine (fully automated casting cell) | – | 1 | Clamping force 1,650 tonnes | – | POWER-CAST Zitzmann, Stockheim |
| 3-D measuring machine with CNC control | – | – | – | – | – |
| CNC turning and machining centres (Fanuc control) | – | – | – | – | POWER-CAST Vobra, Enger |
| Robots for removal and handling of castings | – | – | – | – | POWER-CAST Zitzmann, Stockheim |
Additional services
Reference customers
Quality
Every process step is accompanied and monitored by employees. Modern measuring and testing equipment includes a CAQ system, 3-D measuring machines with CNC control, force testing, X-ray inspection, spectral analysis, leak testing, salt spray fog testing, as well as materials testing of metal and plastic.
| Evidence | Velbert | Enger | Stockheim | Neukirch/Lausitz | Schlierbach | Ortmann (CZ) | Monterrey |
|---|---|---|---|---|---|---|---|
| ISO 9001 | |||||||
| IATF 16949 | |||||||
| ISO 14001 | |||||||
| ISO 50001 |
History
- 1992
Start of magnesium die-casting production at POWER-CAST Zitzmann
- 2003
20 years of magnesium die casting at POWER-CAST Magnetech (according to news archive, anniversary approx. 2023)
- 2021
Commissioning of the group's largest casting cell: fully automated cold chamber die casting machine with 1,650 t clamping force at Zitzmann (seven-figure investment)
- 2023
Siemens AG honours POWER-CAST Ortmann in the "Best Quality" category