Highly automated complete casting production with full traceability.
RÜBIG Alu Deutschland refines aluminium parts and also manufactures mechanically processed aluminium cast chassis parts complete with press-fit bearings at its Pilsting plant. End-to-end production, from the raw part to the end product, takes place in a fully automated processing line from FILL. This ensures parts processing with maximum cost-effectiveness, tested quality and complete traceability.
In a purpose-built new factory, a German premium car manufacturer has been building a new series of fully electric cars since autumn 2025. Innovations of these models include a rear axle carrier made from a single aluminium casting.
Component-specific production plant
RÜBIG Alu Deutschland GmbH & Co.KG in Pilsting (Bavaria, Germany) delivers the component ready for installation with all machining completed. These parts can only be manufactured economically with a very high degree of automation. To facilitate this, Austrian manufacturer FILL Gesellschaft m.b.H developed, built and installed a turnkey, component-specific production plant within only a few months.
The complexity of this process is enormous: after the raw parts have been placed in annealing racks and transported to the heat treatment facility, they undergo crack testing at two manned and one unmanned station. Once the casting burrs have been removed, the parts are machined in machining centres by milling, drilling and thread cutting, and then deburred and cleaned. By pressing in the appropriate rubber bearings, the rear axle carriers weighing around 25 kg receive their vehicle-specific design before undergoing end-of-line testing and being packed into transport racks. The entire process is documented to provide fully traceability for each part.
Maximum efficiency and precision
Three FILL SYNCROMILL C21-80/1500 high-performance machining centres with direct loading and a sophisticated tool change concept facilitate an extremely efficient, space-saving and economical production of complex workpieces with maximum precision. A six-axis articulated arm robot travelling on a linear axis links the three machining centres with the upstream and downstream stations. There, a sophisticated interaction between robots and conveyor lines ensures seamless automated production.
Process reliability and transparency
FILL software solutions out of the CYBERNETICS portfolio link the various plant components and machines within the aluminium parts processing plant. They ensure connection to the customer's ERP system and the seamless recording and storage of all relevant process parameters for efficient operation and reliable component traceability.
"The FILL system enables the reliable and fully traceable production of chassis parts with maximum precision and fewer than ten people directly involved in the process," explains Patrick Hacker, Chief Operating Officer (COO) at RÜBIG Alu Germany. "The resulting low unit costs were decisive in our winning this prestigious contract."
Corporate Data
FILL is a leading international machine engineering company based in Gurten, Upper Austria. With sophisticated high-tech systems and custom manufacturing solutions for metal, plastics and wood, Fill makes its customers the best in their fields. The automotive, aviation, sports and building industries all benefit from Fill's expertise. Since it was founded in 1966, the company has distinguished itself through enormous innovative strength, strong values and the best jobs. "If you are seeking the best solution, shape your future with Fill,” is the guiding principle of the company’s more than 1,000 employees. “We are one!" is their vision and stands for togetherness with the team and with customers, suppliers and partners. The company is 100 percent family-owned and is managed by Andreas Fill (CEO), Martin Reiter (CFO), Alois Wiesinger (CTO) and Günter Redhammer (COO). In 2025, Fill generated revenue of 205 million euros.
If you have any questions, please do not hesitate to contact us:
Fill Gesellschaft m.b.H.
Fillstraße 1, 4942 Gurten
Martina Moserbauer
martina.moserbauer@fill.co.at
Caption:
Image 1:
At its Pilsting site (Bavaria), RÜBIG manufactures aluminium rear axle carriers for a premium car manufacturer, from cast aluminium blanks to ready-to-install assemblies. At the heart of the plant are three FILL SYNCROMILL C21-80/1500 high-performance twin-spindle machining centres.
Photo: Oliver Hallwirth | raumpixel
Image 2:
A six-axis articulated robot travelling on a 20-metre linear axis connects the three machining centres with the upstream and downstream stations.
Photo: P. Kemptner
Image 3:
Ing. Patrick Hacker, CEO of RÜBIG Aluminium Deutschland GmbH & Co.KG:
"The FILL system enables the reliable and fully traceable production of chassis parts with maximum precision and fewer than ten people directly involved in the process."
Photo: Rübig
