As demand for larger and more complex aluminium rail components continues to grow, German manufacturer
Dowaldwerke has invested in a second machining centre from the
Chiron Group to increase productivity, reduce handling and bring more work in-house.
Expanding capacity for long-profile machining
Based in Dippoldiswalde, Saxony, Dowaldwerke GmbH supplies a range of products to the railway and hydraulics sectors. Its rail portfolio includes vacuum toilet systems, interior door systems, partition walls and boarding aids for major European rolling stock manufacturers, while its hydraulics division produces cylinders for agricultural, construction and industrial vehicles.
The company has now added a Chiron Group MILL 3000 machining centre to complement its existing MILL 2000, both of which are used primarily to machine aluminium profiles and tread plates for rail vehicle applications.
Typical components include profiles for interior door systems, boarding aids and platform-edge bridging systems. Many of these hollow aluminium sections exceed 2m in length, creating challenges for machining on existing equipment. Additional clamping operations, repositioning of workpieces and increased handling requirements were extending production times and consuming valuable resources.
At the same time, Dowaldwerke wanted to expand its manufacturing capability and reduce its dependence on subcontractors.
“Since external providers could not cover either the required precision or the required travels, it was clear to us that we would do this in-house in the future, with a solution that produces long workpieces economically and at the same time meets our requirements for quality and productivity,” said Rico Eißler, managing director of Dowaldwerke.
One setup, greater productivity
Having used a MILL 2000 machining centre successfully for several years, Dowaldwerke was already familiar with the Chiron machine concept and its capabilities. The company also places considerable emphasis on involving machine operators in investment decisions, recognising the importance of usability and day-to-day efficiency on the shopfloor.
According to cutting machine operator Lisa-Marie Ganz, the familiarity of the platform was a significant factor in the decision. “We were already familiar with the machine concept, are familiar with the operation and have had good experience with it,” she said.
Working closely with Dowaldwerke, the Chiron Group developed a bespoke manufacturing concept based on its MILL Series platform. The primary objective was to allow long profiles to be machined in a single setup wherever possible, reducing both the number of clamping operations and the associated reference points.
A key element of the solution is a specially designed swivel bridge, effectively serving as a fourth axis. This enables workpieces to be rotated through 90°, allowing side machining operations to be carried out without reclamping.
“The challenge was to machine the workpieces in one clamping if possible,” explained Frank Scheibe, technical consulting and sales specialist at the Chiron Group. “This required a precisely coordinated production concept that offers sufficient flexibility for the various profile types and geometries.”
The approach has delivered several benefits. Machining operations can now be completed directly on the workpiece without repositioning, improving throughput while reducing handling and setup times. The clamping concept has also been simplified, with a single clamping jaw often sufficient for complete profile machining. In addition, operators can machine between clamping points, enhancing flexibility and process reliability.
Dowaldwerke has also benefited from the machine’s rapid tool-changing capability. David Steinigen, head of work preparation, noted that frequent tool changes are a normal part of production and that shorter changeover times provide a clear advantage within machining programmes.
More than a machine investment
While the technical capabilities of the MILL 3000 were central to the investment decision, Dowaldwerke says its long-standing relationship with Chiron was equally important.
According to Eißler, the company’s experience with both the equipment and the support provided over the years created confidence in selecting another Chiron machine.
“Why did we choose a Chiron Group machine again? Ultimately, it is, beyond the qualities of the machining centres, the cooperation. Very cooperative, very solution-oriented,” he said.
That partnership has continued beyond installation. Scheibe remained closely involved throughout commissioning and subsequent optimisation activities, coordinating with Chiron’s teams in Tuttlingen and local service engineers to implement adjustments and modifications as production requirements evolved.
The result is a manufacturing solution that not only supports Dowaldwerke's growth strategy but also streamlines production of long aluminium profiles through fewer setups, reduced handling and shorter throughput times.
For Dowaldwerke, the investment reinforces a relationship built on technical performance, practical problem-solving and operator acceptance. With the new MILL 3000 now in operation, the company is well positioned to meet increasing demand for high-precision rail components while maintaining efficiency and flexibility on the shopfloor.