PRODUCTION | Precision parts for big engines

From concept to production:

We specialize in the production of high-precision components following the specifications of our customers. From the first draft to the delivery of the finished product we offer all the manufacturing steps  –  no matter whether for one of a kind or on an industrial level.

Primary material
Most of the strictly traceable machining processes in OPTIMA precision parts production begin with the processing of bar material from only renowned manufacturers in selected grades. In addition to checking the material composition, grinding the bar diameter is often the first processing step.

• Material procurement according to customer requirements
• A large number of different special alloys are in stock
• If necessary, support with material design
• Independent in-house incoming goods inspection (spectral analysis, hardness testing, structural examinations)
• In-house raw material preparation (bar grinding, chamfering of the bar material)

Machining before heat treatment
The correct soft machining forms the basis for the cost-effective, stable manufacturing process of most precision parts. OPTIMA uses extensive and diverse machinery for this purpose, but external partners are also happy to be called upon for special tasks.

• Short lathes with up to 3 turrets and up to 36 driven tools, bar capacity up to 65 mm
• Multi-spindle lathes up to 8 spindles (conventional and CNC)
• Lathe with up to 8 axes, diameter range 2-32mm
• Deep hole drilling (up to 4 spindles), diameter range 1-15 mm
• Milling 3/4/5 axis machining with up to 40 tools
• Ring lathes 0.3 – 6mm
• Thread/knurling rollers

Hardening process
When it comes to hardening processes, it is also important to use the process that suits the material and the hardening goal precisely and reliably. Being able to offer sophisticated know-how in-house is one of the keys to lean production of medium quantities in long process chains.

• Inert gas hardening
• Case hardening
• Salt bath hardening
• Vacuum hardening
• Case hardening vacuum (LPC)
• Gas nitriding
• Gas nitrocarburizing
• Tenifer nitriding
• Salt bath nitriding QPQ
• Glow
• HF hardening (partial inductive hardening or soft annealing)
• HF bar hardening (up to 3m bars)
• Supercooling (chest -80°C or nitrogen -196°C)
• Well-equipped hardness laboratory for all common material analyses (hardness testing, sample preparation, structural analysis)
• Special component cleaning of complete oven batches (washing system)
• Belt blasting system

Superfine treatment
Optima has always been about precision. The precise hard machining of series components is now anchored in OPTIMA's DNA. That's why it's not surprising that we can now offer a unique range of grinding processes and the appropriate, experienced specialists. Only this combination ensures that stable, capable processes can be developed and introduced into series production in the shortest possible time.

• Grind
• Centerless external cylindrical grinding
• External cylindrical grinding in a centerless groove
• External cylindrical grinding between centers (straight/oblique)
• Internal grinding
• Lapping
• Honing
• Internal honing
• Professional honing
• Double-side face grinding
• Superfinishing
• Plan finishing
• External circular continuous machining
• External circular grooving machining
• Vibratory grinding
• Round trough vibrators
• Centrifugal grinding systems
• High gloss polishing
• Rotary drums
• Hard turning
• Hard milling
• Micro grinding (own micro grinding machines)
• Flow loops (flow calibration and DFL)

Quality management
At OPTIMA, quality begins with the people and the processes. The integrated quality management system is the foundation of our actions, stable, capable processes are our everyday life and high-quality products are the result.
Preparation, support, and testing are the essential components of quality assurance in the development and maintenance of product quality.

• Integrated quality management system certified according to ISO 9001, 50001, and 14001
• 100% tests using inline sensors, measuring controls, and automatic testing machines as well as random testing using automated measuring processes from coordinate measuring machines, digital measuring projectors, and shaft scanners
• Worker self-testing with hand-measuring devices, measuring devices, and measuring devices in production
• Measuring machines and measuring devices in three air-conditioned measuring rooms
• Tactile and optical coordinate measuring machines
• Shape measuring machines
• Roundness measuring devices
• Contour measuring devices
• Surface measuring devices
• White light interferometer
• Sampling and requalification according to IATF and VDA (PPAP, PPF)
• Internal measuring equipment calibration according to DIN EN ISO 17025
• As a progressive, dynamic, and future-proof company, we make no compromises when it comes to quality or environmental protection. For this reason, we have defined binding standards according to IATF 16949, ISO 9001, ISO 50001, and ISO 14001 as a working basis for every employee. 

Assembly
Precision is not just in the individual parts, but also in the interaction of the matching individual parts. The economic key is to ensure the necessary precision for reliable function. And this with the least possible effort. In addition to the production of individual parts, OPTIMA is also very intensively involved in the assembly and testing of assemblies.

• Special component cleaning and temperature control
• Precision measurement in the sub-micrometer range and classification of components as a prerequisite for the fit pairing
• Assembling mating parts and assemblies (e.g. pressure relief valves, piston/housing combinations)
• Functional test
• Leak test
• Residual dirt analysis to prove our customers' cleanliness requirements

Valve Tappet - Cam Followers Machining Division
The Tappet (cam followers) machining unit is located in two places on the same Industrial complex. The current machining capacity of Tappet (cam followers) is thousands per Annum and we have a dedicated state-of-the-art manufacturing facility for Tappet machining and surface treatment with the latest metrology and metallurgy lab to measure all the critical parameters of the Tappets. Most machines are highly productive CNC and SPM with the latest technologies to produce Tappets and Lifter bodies. The Tappet / Lifter bodies are made from Chilled Grey Iron, Ductile Iron,  Hardenable Grey Iron, Hot and Cold Forged Steel, and Steel bars. The types of tappets are Mushroom, Barrel, Split, hollow, Bucket, and Roller Assembly. Optima has a highly competent team to handle manufacturing activities flawlessly. The Tappet Division has been vital to Optima’s consistent growth and it is IATF  16949 & ISO 14001 & ISO 45001:2018 certified.