Chiron Group Partners with Mapal for Truck Parts Production in North Carolina

Charlotte, North Carolina – Chiron America Inc., a subsidiary of the Chiron Group, has once again partnered with Mapal, a leading precision tooling manufacturer, to deliver a turnkey solution for a truck manufacturer’s production line. The project, which involves the production of front transmission housings for large truck diesel engines, marks the continued collaboration between these two companies in North America. This collaboration underscores their commitment to providing high-quality, precision manufacturing solutions tailored to meet the specific needs of the U.S. automotive sector.

Chiron’s North American Manufacturing Focus

Chiron Group, with a presence in the U.S. since 1993 and a factory in Charlotte since 2001, specializes in adapting its German-engineered machines to meet the unique demands of U.S. industry. The 7,000m² Charlotte facility, employing 100 people, focuses on adapting high-precision machines for a variety of industries, including automotive, aerospace, and medical technology. The company offers tailored turnkey solutions for customers, integrating software, clamping fixtures, and tools to ensure the machines are ready for immediate use upon delivery.

Mapal’s Expertise in Precision Tooling

Operating in the U.S. with facilities in Port Huron, Michigan, and Fountain Inn, South Carolina, Mapal has long been a trusted partner for Chiron. The company’s two U.S. production sites focus on the manufacture and reconditioning of high-precision tooling, including reamers, drills, form cutters, and tools for composite machining. Mapal’s U.S. operations reflect its commitment to customer proximity and support, which has been crucial to its success in North America.

Customized Solutions for Complex Truck Parts

In this most recent project, Mapal provided a comprehensive tooling solution for the production of front transmission housings made from aluminium A380 die-casting alloy. The customer, a truck manufacturer, aims to produce 120,000 units per year for the next six to eight years. With a production run potentially reaching up to one million units, the precision required for this part is critical.

To meet these stringent requirements, the DZ 25 P five-axis double-spindle machining centre, developed by Chiron, was selected. This machine offers high rigidity, enabling high-axis acceleration and rapid traverse speeds for dynamic and precise machining. The machine can process two 800 x 800mm components simultaneously, ensuring efficient production.

Mapal’s Custom Tooling

For the task, Mapal supplied 78 custom tools, including 33 PCD tools and 45 carbide cutting-edge tools. A significant number of these tools feature special geometries and dimensions to accommodate the complexity of the component and the selected machining strategy. By consolidating machining steps into fewer tools, Mapal has optimized cycle times, improving both machining efficiency and precision. The tools used in this project also maintain high accuracy under demanding conditions, ensuring the parts meet tight tolerance specifications of 25µm for diameter tolerances ranging from 8 to 10µm.

Successful Collaboration

Both Chiron and Mapal have expressed satisfaction with the outcome of the project. Jesus Flores, lead project engineer at Chiron, commented, “Mapal’s tool design and application support have been outstanding. The tools perform excellently, and their proactive approach to collaboration has been invaluable.”

Evan Osantoski, Mapal’s sales and application engineer, also praised the collaboration, stating, “We are proud to have delivered this large tool package within tight deadlines, and we look forward to continuing our successful partnership with Chiron in the U.S.”

As both companies continue to grow in the U.S. market, they are already preparing for future projects together, demonstrating the strength and reliability of their long-standing partnership.