Aluminium customer foundry with vertical integration: castings from design through casting, heat treatment and CNC machining to the ready-to-install component.
TAGUSS GmbH
Römerstraße 25, 89278 Nersingen (DE)New on Amplifa
Foundry with full vertical integration
TAGUSS is a customer foundry for aluminium casting based in Nersingen near Ulm. The company produces ready-to-install aluminium castings in various moulding and casting processes: sand casting using the cold-box resin process (no-bake) and the green sand process on a fully automated bentonite moulding line, gravity and low-pressure die casting, the chemical-free vacuum moulding process (V-Process), and 3D sand printing of moulds and cores. The casting processes are complemented by extensive vertical integration: heat treatment, CNC machining with up to 6 axes, in-house toolmaking, and R&D with FEM analysis and casting process simulation (MAGMA). Customers thus receive everything from a single source – from the idea to the inspected, ready-to-install component. With around 120 employees, TAGUSS, a family business in which the foundry craft has been practised for three generations, supplies industries such as rail transport, medical technology, mechanical engineering, energy distribution, the vacuum industry, robotics and e-mobility in Europe and worldwide.
- Site
- Nersingen
- Processes
- Sand casting using the cold-box resin moulding process (no-bake, furan resin, phenolic resin,, Sand casting using the green sand process (Seiatsu, air-flow squeeze process, fully automated, Gravity die casting, Low-pressure die casting, Vacuum moulding process (V-Process), 3D sand printing process (3D printing of moulds and cores, quartz sand 0.2 mm layer thickness), Heat treatment (controlled heat treatment of aluminium castings, quenching, heat treatment, CNC machining (milling, drilling, turning, up to 6 axes)
- Materials
- Aluminium, Aluminium alloy, Aluminium casting alloys according to EN 1706, Quartz sand (moulding material for 3D sand printing), Bentonite-bound moulding material (green sand), Sand casting using the cold-box resin moulding process (no-bake, furan resin,, Sand casting using the green sand process (Seiatsu, air-flow squeeze process), Gravity die casting
- Certificates
- ISO (heat treatment), NADCAP (heat treatment), ISO certification heat treatment, NADCAP certification heat treatment
- Employees
- approx. 120
- Industries
- Rail transport, Medical technology, Gearbox manufacturing, Shipbuilding, Energy distribution, Electromobility
- 01
R&D: castability-optimised design, FEM analysis, MAGMA casting simulation
- 02
Toolmaking: patterns, casting tools and fixtures
- 03
Foundry: sand casting, die casting, V-Process or 3D sand printing
- 04
Heat treatment according to EN 1706 and customer requirements
- 05
CNC machining (turning, milling, drilling up to 6 axes)
- 06
Quality inspection: metallurgy, NDT, metrology
- 07
Logistics: just-in-time delivery with distribution centre in Nersingen
Casting Processes and Materials
Sand casting using the cold-box resin moulding process (no-bake, furan resin,
For low annual volumes (20–2,000 units) and large castings from 30 to 3,000 kg with high design freedom.
Sand casting using the green sand process (Seiatsu, air-flow squeeze process)
Fully automated bentonite moulding line (flask size 1500 × 1050 mm) for series of 300 to 20,000 units with 10 to 120 kg component weight.
Gravity die casting
Permanent steel mould for 1,000–20,000 units with high surface quality and strength, 5 to 25 kg per component.
Low-pressure die casting
Automated, laminar bottom-up filling for 1,000–30,000 units with improved casting quality and low porosity, 15 to 250 kg.
Vacuum moulding process (V-Process)
Chemical- and water-free process with 100 % recyclable moulding material for 100–10,000 units with high surface quality, 10 to 100 kg.
3D sand printing of moulds and cores (quartz sand, layer thickness 0.2 mm)
For prototypes and one-off parts (1–10,000 units) with virtually unlimited dimensions, 5 to 500 kg component weight.
Aluminium casting alloys according to EN 1706
Material basis for all casting processes, including controlled heat treatment for targeted adjustment of mechanical properties.
Nersingen Site
Nersingen
DEHeadquarters, foundry, production, distribution centre
- Part weight / size
- Castings 5–3,000 kg depending on process; flask max. 1560
- Lot size
- 1 to 30,000 units depending on casting process
- Materials
- Aluminium casting alloys according to EN 1706
- Fully automated bentonite moulding line (Seiatsu/air-flow squeeze process)
- 3D sand printer (job box, layer thickness 0.2 mm)
- CNC horizontal lathes with tool magazine
- Vertical turret lathes
- 3-, 4- and 5-axis machining centres
- Chained 6-axis turn-mill machines
- AGV systems for tool supply
- Fully automated heat treatment systems
- CMM measuring machines
- 3D laser scanners
- X-ray systems (radiography, digital radioscopy)
- Tensile testing machines
- Spectrometers
- MAGMA casting process simulation
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Sand casting using the cold-box resin moulding process (no-bake, furan resin, phenolic resin,Casting | – | – | 30 kg – 3000 kg | 20 units – 2000 units | Aluminium |
| Sand casting using the green sand process (Seiatsu, air-flow squeeze process, fully automatedCasting | – | 1500 mm × 1050 mm | 10 kg – 120 kg | 300 units – 20,000 units | Aluminium |
| Gravity die castingCasting | – | – | 5 kg – 25 kg | 1000 units – 20,000 units | Aluminium |
| Low-pressure die castingCasting | – | – | 15 kg – 250 kg | 1000 units – 30,000 units | Aluminium |
| Vacuum moulding process (V-Process)Casting | – | – | 10 kg – 100 kg | 100 units – 10,000 units | Aluminium |
| 3D sand printing process (3D printing of moulds and cores, quartz sand 0.2 mm layer thickness)Additive | – | – | 5 kg – 500 kg | 1 unit – 10,000 units | Aluminium |
| Heat treatment (controlled heat treatment of aluminium castings, quenching, heat treatmentHeat treatment | – | – | – | – | Aluminium |
| CNC machining (milling, drilling, turning, up to 6 axes)Machining | – | – | – | – | Aluminium |
| CNC turning (horizontal lathes with tool magazines, vertical turret lathes, CAD/CAM)Machining | – | – | – | – | Aluminium |
| CNC milling (3-axis, 4-axis, 5-axis machining centres, chained 6-axis turn-mill machines)Machining | – | – | – | – | Aluminium |
| Toolmaking (design and manufacture of casting tools, patterns and fixtures)Engineering | – | – | – | – | Aluminium |
| R&D / Engineering (castability-optimised design, FEM analysis, MAGMA casting process simulation,Engineering | – | – | – | – | Aluminium |
| Quality assurance: NDT (radiography, digital radioscopy, red-white dye penetrant inspection andTesting | – | – | – | – | Aluminium |
| Destructive testing (tensile testing machines, strength testing, fatigue tests forTesting | – | – | – | – | Aluminium |
| Metrology (CMM measuring machines, 3D laser scanner, moulding sand analysis)Testing | – | – | – | – | Aluminium |
| Metallurgy (melting treatment, spectrometer, density index, thermal analysis, microscopy)Casting | – | – | – | – | Aluminium |
16 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Fully automated moulding line (Seiatsu / air-flow squeeze process, bentonite green sand) | – | – | Flask size 1500 x 1050 mm (max. 1560 × 1110 × 750 mm according to industry websites) | – | Nersingen |
| CNC lathes (horizontal with tool magazine) | – | – | – | – | Nersingen |
| Vertical turret lathes | – | – | – | – | Nersingen |
| 3-axis milling machines | – | – | – | – | Nersingen |
| 4-axis machining centres | – | – | – | – | Nersingen |
| 5-axis machining centres | – | – | – | – | Nersingen |
| 6-axis turn-mill machines (chained) | – | – | – | – | Nersingen |
| AGV systems (tool supply for the machine fleet) | – | – | – | – | Nersingen |
| CMM measuring machines | – | – | – | – | Nersingen |
| 3D laser scanner | – | – | – | – | Nersingen |
| X-ray systems (radiography, digital radioscopy) | – | – | – | – | Nersingen |
| Tensile testing machines | – | – | – | – | Nersingen |
| Spectrometers | – | – | – | – | Nersingen |
| 3D sand printer (job box, layer thickness 0.2 mm) | – | – | Dimensions virtually unlimited according to website | – | Nersingen |
| Heat treatment systems (fully automated, furnace) | – | – | – | – | Nersingen |
| MAGMA software (casting process simulation) | MAGMA | – | – | – | Nersingen |
Additional services
Quality Assurance
The quality system encompasses strictly controlled processes from metallurgy (spectrometer, density index, thermal analysis, microscopy) through non-destructive testing (X-ray digital and on film, FPI, ultrasound) to metrology with CMM and 3D laser scanner. Destructive testing on tensile testing machines as well as fatigue tests for rail bogie components ensure first-article and series approval.
| Evidence | Nersingen |
|---|---|
| ISO certification heat treatment | |
| NADCAP certification heat treatment |
Tradition in Its Third Generation
The foundry craft has been practised in the family for three generations; the company is today run as a family business in its second generation.