Ace’s setup times in CFRP post-processing much reduced with HG Grimme SysTech

Ace acquired the identical machining centres, each with two tables and a shuttle as well as a Siemens 840d sl control system, between 2016 and 2024. Consistent operation and machine tables with the same hole pattern and a fixed zero point also contribute to short setup times. Furthermore, Ace can post-process the CFRP parts on all machines from HG Grimme SysTech interchangeably and without any quality limitations.

CFRP dust is extracted

The milling systems are suitable for workpieces with external dimensions of up to 2,000 x 2,500 x 650 mm, which can be machined with exceptional dynamics thanks to rapid traverse speeds of 80 m/min in X/U/Y and 30 m/min in Z.

Double tables and shuttles result in a machine length of just under 11 metres and a width of slightly less than six metres. This simultaneously provides sufficient space for good accessibility to the machine table and milling head from all sides.

The components to be machined are up to 2,000 x 2,500 mm in size, with thicknesses between 1 and 3 mm, and batch sizes usually vary between 500 and 10,000 pieces.

Around two-thirds of the products are visible parts, predominantly for car bodies, particularly fenders and hoods. The remaining parts are structural components such as monocoques for the drivetrain, battery trays for electric vehicles, and paneling for B-pillars and centre struts.

Given the significant dust generation during CFRP milling, CNC machining centres from HG Grimme SysTech are completely encased, and an extraction system removes many airborne particles directly within the enclosure. Furthermore, the components are manually cleaned again with high pressure after machining.

Ace manufactures most CFRP components using the closed RTM process

Ace manufactures 90% of the CFRP components and assemblies using the closed RTM process. In this process, textile preforms are cut and prepared into layups, which are then placed in presses, injected with resin, and cured into shells. The edges of the two, or less frequently three, shells still need to be milled before they are subsequently bonded together to form the carbon fibre part.

After contour and trim milling, the bonded and painted components are inspected before Ace delivers them to its customers’ assembly lines. This includes well-known brands such as Lamborghini, Porsche, Aston Martin, Bugatti, BMW, Mercedes, AMG, Audi and Volkswagen. The most important customers from the aerospace industry are Airbus and Boeing.

Peter Klaus Gröschl, Production Manager and one of the Managing Directors of Ace, praises not only the solidity and reliability of the systems but also the service provided by HG Grimme SysTech. His conclusion: “At HG Grimme, they understand something about processing composite materials, and the communication is at eye level. The company is down-to-earth. We enjoy working together.”

Cover photo: The shuttle system with 2 tables reduces the downtime of the milling centers to two to three percent of the machine running time – compared to 40 to 45% for a system with only one table (source: HG Grimme SysTech)