Heather Miller
When Managing Director Michael Oswald’s father founded ALUTECTA in 1970, he was a mechanical engineer from a modest background who set out to build something of his own in rural Germany. Five decades later, ALUTECTA—with a motto of “aluminum in form, color, and function”—has grown into a modern, family-run company with more than 130 employees.
As an expert in both processing and machining aluminum sheets and profiles in addition to surface treatments, the company delivers high precision, customized aluminum products for many industries, from construction to automotive, healthcare, and more. “If you name it and it’s aluminum, we can do it,” Oswald says.
Over the years, ALUTECTA expanded to include more services and different types of projects. But they also collected many different pieces of software along the way. Up until November 2023, there were up to five programs, including two different CAD systems, plus three CAM solutions for the different machines. Then ALUTECTA was introduced to Autodesk Fusion, and many inefficiencies were revealed. By adopting Fusion, the company replaced all the software with one platform and gained incredible new capabilities for optimization and time savings.
“Since we handle multiple projects every day from a single piece to the creation of complete sheet metal facades, Fusion constantly helps us solve our challenges,” says Tom Stasek, production manager, ALUTECTA. “This is especially true for the combination of multiple functions and controlling the entire machining fleet within a single software package.”
“The support from the Autodesk team is incredible and a major contributor to our successful use of Fusion today,” Oswald adds.
New workflows and time savings
Since ALUTECTA serves many different markets, their customers also run the gamut of digitalization and varying file types. Previously, they had to run customer files through a complex chain of different software programs, each tailored to specific machines, making the process time-consuming and rigid. Now, with Fusion, they can handle all tasks—from file import to milling setup—in one workflow.
Elevate your design and manufacturing processes with Autodesk Fusion
“Now, we’re quite free with Fusion,” Oswald says. “We put in the file from the customer and do all the tasks right inside Fusion. Then, at the end, we can decide which machine to use. The work preparation and machine setup time have been cut nearly in half.”
Milling operations are easier—and faster—than ever before, with an estimated 30% in time savings.
“Flexibility in machine utilization and time savings is huge,” Stasek says. “Previously, a separate milling program for the same component had to be created for each machine. With Fusion, we can define the milling operations on a component once and then easily create an NC program for all machines with a simple mouse click, without having to repeat the same task multiple times.”
“Another major advantage of Fusion is the ability to animate, simulate, and manufacture these components,” he adds. “Especially in the manufacturing workspace, I see the advantage of having many manufacturing methods available: milling, turning, laser cutting, and even slicing for 3D-printed components.”
“One of my favorite Fusion features is the ability to model and integrate components three-dimensionally and define the machining operations. Combined with the ability to simulate programmed machining operations and even designing sheet metal edge elements directly and creating a flat pattern and associated milling program, we can work more efficiently and precisely.”
—Tom Stasek, Production Manager, ALUTECTA
Better results with Fusion
By using Fusion for its entire workflow, ALUTECTA can respond to customer needs faster, whether it’s tweaking a component design or scaling to a full production run. With CAM in Fusion, the company is taking advantage of more of its own machines and capabilities. For example, the company’s use of a 5-axis milling machine with 10 independently moving clamping blocks is now fully utilized, thanks to Fusion.
Nesting is also used to place multiple components as efficiently as possible on the sheet metal, reducing waste. ALUTECTA takes full advantage of the Fusion Manufacturing Extension for measuring and probing on the 5-axis milling machine as well as performing 5-axis simultaneous machining if required.
“You don’t even need statistics or numbers to relay the improvements we have with Fusion and the Manufacturing Extension,” Oswald says. “You just see it and experience it.”