Mapal continues to position itself as a leading productivity partner, expanding its offering far beyond traditional tooling. While the company has long provided services such as tool design, tool management and production line support, it is now taking a decisive step forward by delivering complete turnkey solutions — from process design through to achieving process capability. Artificial intelligence (AI) is also firmly on the horizon.
Process design is critical, setting the cost framework for each component. Cycle time and process reliability are key factors. Mapal has always had deep tool expertise, but until recently lacked the ability to go into detail in areas such as clamping fixtures, programming and process acceptance. That changed with the acquisition of Italian specialist
X-Pro last year, enabling Mapal to support customers at an early stage of component industrialisation through feasibility studies and optimised machining strategies. The result — guaranteed cycle times and quality specifications.
Stephan Köstler, global head of machines and services at Mapal, said: “The aim is an efficient and stable manufacturing process. As early as the conceptualisation phase, clamping fixtures are designed to meet requirements for quality and process reliability — tailored to the stresses and strains involved in the machining process.
“A simulated and optimised NC program ensures that all machining steps can be achieved collision-free before the first component has even been produced. The installation and commissioning of the process under real conditions on the production line with proof of process capability is the final step.”
Tool managementProjects using these new capabilities have already been delivered successfully, with Mapal assuming full responsibility and meeting customer expectations within eight to 12 weeks. Mapal’s holistic approach also extends to tool management — a concept that goes far beyond supplying tools. At its core is continuous optimisation of machining processes and the entire tool cycle, from procurement and storage to pre-setting and reconditioning. Digital processes, standardised workflows and close collaboration with production underpin this service.
The full integration of Mapal’s cloud-based platform c-Com in 2025 reinforces this strategy, bringing together data, tools and processes in one secure, globally accessible system. Customers benefit from high tool availability, optimised inventories and streamlined logistics, while real-time analytics provide insight into consumption, costs and performance across multiple sites.
With over 100 active projects worldwide and a dedicated competence centre in Aalen, Mapal sees tool management as an integral part of modern manufacturing — not an optional extra. Mapal is also pushing digital integration through its Productivity as a Service (PRODaaS) concept, which connects live machine data to optimise processes. An initial research project proved successful, and now the sequel—PRODaaS@SCALE — takes automation further.
Mr Köstler explained: “With PRODaaS, the aim was to allow the experiences with productivity gains made in ongoing series production to flow back in a structured way, in order to get much closer to the ideal point in the initial component design.” The new project introduces AI-driven self-regulation, enabling systems to incorporate application experience directly into process design. During planning, AI will deliver significantly better machining settings through customer-specific training.
The initiative aligns with Germany’s Manufacturing-X programme, which aims to overcome the challenge of scaling shared data use without compromising data sovereignty. Partners include Zoller, Walter Formenbau, Fraunhofer IPA, VDMA and woodworking machine manufacturer Weinig. Mapal leads the consortium, reinforcing its role as a driver of innovation.
With turnkey solutions, digital platforms and AI-based projects, Mapal is setting new standards for productivity and efficiency. The company’s expanded offering positions it as a pioneer in modern manufacturing — ready to meet the challenges of Industry 4.0 with tailored, future-focused solutions.