Automated ATOS 5 3D scanning knee implant components on a fixture inside ScanBox.

The world's largest hand-molding foundry

Technology supplier specializing in advanced casting technology for mechanical and plant engineering

Based in Krefeld, Germany, Siempelkamp Giesserei is the largest hand-molding foundry in the world. It produces large and heavy castings with a weight of up to 320 tons for the fields of energy conversion, raw material processing as well as press construction and mechanical engineering. The company has a longstanding history and experience in foundry technology and attaches great importance to safe work processes, environmental protection and high product quality.

Siempelkamp is an important global supplier for the industry. To ensure a smooth production process for top-quality castings, the company relies on measuring technology from ZEISS. The ZEISS ATOS LRX 3D scanner enables Siempelkamp to carry out an effective quality assurance while increasing energy efficiency and using valuable resources sustainably by minimizing scrap.

Metrology is part of a comprehensive digitalization strategy. Full-field measurement data enable the company to digitally track the part geometry of all products throughout the entire process – from the model to the casting mold to the final cast part.

Exclusive insights: Siempelkamp Giesserei

Gain insights into the world of the Siempelkamp foundry and discover the use of ZEISS ATOS LRX in the casting industry.

Optimizing the casting production: Vital influence of the ZEISS technology

No limits: Innovative processes for measuring parts of all sizes

For more than 10 years, Siempelkamp Giesserei has been profiting from the advantages of the ZEISS ATOS 3D scanner. To minimize the manual effort, Siempelkamp Giesserei has decided to use the latest scanner in an automated setup. Together with ZEISS, Siempelkamp Giesserei has installed the world's largest non-contact robot measuring cell with the aim of controlling the production quality of cast parts. The centerpiece of the measuring cell is the ZEISS ATOS LRX 3D scanner that has been specifically developed for large measuring areas and rough production conditions.

The automated project measuring cell captures large parts and generates full-field data. During the inspection, the software guides you through the entire process, from the automatic programming of the robot to data acquisition and inspection to reporting – all with a single system. This high-tech solution allows for a fully automated inspection of parts with an impressive length of over 20 meters.  By enabling comprehensive analyses, this innovation increases the efficiency and accuracy of measurement results.

Arndt Merten, Head of the quality department at Siempelkamp Giesserei GmbH

Being able to work with one of the most modern systems currently available on the market is a great benefit for Siempelkamp and for me personally.

Arndt Merten

Head of the quality department at Siempelkamp Giesserei GmbH

ZEISS ATOS LRX – The specialist for large parts

Large measuring area meets ultra-bright laser light source

ZEISS ATOS LRX is specialized in 3D scans of large-volume parts. The sensor provides full-field data with a highly detailed resolution in next to no time. Thanks to its ultra-bright laser light source and the large measuring area, significantly fewer scans are required. In a single scan, ATOS LRX captures 12 million individual measuring points. With a dustproof and splashproof housing, this solid system is designed for rough production conditions and thus perfectly suited for industrial use.

Thanks to the specifically developed project measuring cell, Siempelkamp Giesserei can now also use ZEISS ATOS LRX as an automated solution. Based on the captured measuring data, the software automatically visualizes surface deviations between the 3D actual coordinates and the CAD data. These results help to quickly identify, analyze and resolve quality issues. Due to the full-field measuring data, the company has a continuous digital quality control.

Tailored metrology for custom-made castings

Discover impressive performance and success in numbers and facts.

  • 320 tons

    This modern technology enables a fully automated part inspection. Cast parts weighing up to 320 tons can be inspected for quality quickly and without any laborious alignment.

  • 3 times faster

    With the automated project measuring cell, Siempelkamp Giesserei achieves a scanning speed that is three times faster than manual scans.

  • 23.5 meters

    At 23.5 meters, Siempelkamp Giesserei holds the world record for the longest cast part. When it comes to scanning this type of cast parts quickly and precisely, the large measuring area of ZEISS ATOS LRX is the ideal solution.

Effective inspection software

ZEISS INSPECT is the metrology software for all challenges

ZEISS INSPECT Optical 3D

ZEISS ATOS LRX is equipped with the powerful ZEISS INSPECT Optical 3D software. From full-field data acquisition to mesh processing to trend analysis and digital assembly, the software supports every process step.

Back projection is a feature that is frequently used for the processing of cast parts to directly project grain points from the software on the part. Thus, large cast parts can be marked quicker and more precisely. Providing a continuous workflow and user-centered operation, the software is intuitive and user-friendly. Smart features allow for a quick and automated programming of the measuring cell, minimizing the required effort.

Dr. Georg Geier, Managing Director at Siempelkamp Giesserei GmbH & Siempelkamp Metallurgie GmbH

To achieve precise manufacturing of such large components, it is essential to ensure the accuracy of the details, which, of course, cannot be achieved without the use of high-precision metrology.

Dr. Georg Geier

Managing Director at Siempelkamp Giesserei GmbH & Siempelkamp Metallurgie GmbH

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Siempelkamp Giesserei GmbH

For more than 100 years, Siempelkamp Giesserei has been producing large and heavy ductile iron castings at a high quality for a wide range of industries at its site in Krefeld, Germany. The company is part of the Siempelkamp Group, a group of companies operating worldwide in the fields of mechanical and plant engineering as well as casting technology. According to the principle Intelligent Engineering for Future Generations, more than 3,000 employees ensure that the Siempelkamp Group maintains its leading technological edge in the world.