Powertrain

Discover cutting-edge manufacturing solutions for smarter, more efficient powertrains with GF Machining Solutions. From impellers to injection nozzles, transmissions to exhaust housings, our know-how in advanced technologies such as metal additive manufacturing, combined with EDM and precision milling, enables faster cycles, unmatched accuracy, and cost-effective production, as well as spanning quick model changes with our System 3R tooling and flexible automated lines.

A range of solutions for your applications

Impellers

Impellers are vital for the efficient performance of all smart hybrid powertrains. With GF Machining Solutions, achieve the fastest cycle times using field-proven quick model change technology. Enjoy seamless accuracy, reduced setup times, and enhanced productivity for unmatched reliability.

Turbocharger housings

Speed up your design cycles with prototyping and volume production using our cutting-edge solutions. Our advanced metal additive manufacturing, combined with precise Milling and EDM technologies, offers a complete process to achieve cost efficiency and scale production effortlessly.

Injection nozzles

Injection nozzles are key to improving emissions and mileage in powertrains. New designs with reverse tapers and ultra-fine accuracy require expertise. GF Machining Solutions leads the way with a complete, closed-loop solution to meet high-volume demands with precision.

Transmissions

New Energy Vehicle powertrains feature innovative designs to enhance power and improve emission efficiency. These complex designs demand advanced molds and agile tooling, seamlessly connected with EDM and Milling technologies for precision and efficiency.

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Turbochargers and impellers

Turbochargers

  • Containing impellers that rotate at up to 300,000 rpm with minimal noise levels, turbochargers ensure a consistent and smooth airflow into the system, playing a crucial role in meeting emission standards for various hybrid powertrains in New Energy Vehicles (NEVs).
  • Turbochargers are also integral to hydrogen-powered fuel cell vehicles, helping optimize performance and efficiency across different powertrain technologies.
  • Turn to GF Machining Solutions for unique, field-tested technologies that deliver reliable and efficient results for cutting-edge automotive applications.

Impellers

  • Crafted from high-performance materials like Inconel, stainless steel, and aluminum alloys, impellers are designed to withstand intense forces in the final stage of compression.
  • GF Machining Solutions ensures the fastest cycle times for impeller machining, eliminating the need for further balancing.
  • Our System 3R tooling provides fast model changes, reducing waste with perfect reproducibility and reliability.
  • Our solutions guarantee impellers of any size perform reliably under extreme heat and stress.

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Turbocharger design

  • Turbochargers are essential for achieving optimal efficiency in modern vehicles, helping meet stringent emission standards while boosting engine performance. Their designs are increasingly complex to enhance power and fuel efficiency.
  • Different materials are utilized for turbochargers, depending on the specific segment and performance requirements. These include lightweight and heat-resistant aluminum, ideal for certain turbocharger components. Hard Materials such as steel alloys, used for parts that experience high stress and extreme temperatures.
  • GF Machining Solutions offers proven, cost-effective solutions from prototype to volume production. Explore our expertise and tailored solutions in our White Paper!

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Fuel injection nozzles

  • Our fuel injection nozzle process includes inline measurements and quality checks to ensure precision. QR-coded outputs are seamlessly loaded into trays for easy tracking and quality confirmation.
  • Achieve precise nozzle positioning with our advanced machining techniques, ensuring optimal performance and reliability.
  • Our technology eliminates burrs and heat-affected zones, ensuring high-quality, durable parts that meet the most stringent standards.
  • Benefit from our comprehensive engineering solutions, combining years of experience and cutting-edge technology to deliver efficient, high-performance fuel injection nozzles.

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Exhaust

  • Quickly create metal prototypes for critical exhaust parts, reducing time to market while maintaining cost-effectiveness.
  • Significantly reduce the number of molds and parts required, with a 20:1 ratio, similar to motorsports applications, streamlining production.
  • Leverage GF Machining Solutions’ advanced metal additive technology and post-processing solutions to achieve top-tier performance for automotive and exotic vehicles.
  • Support high-performance manufacturers in refining and perfecting exhaust designs for optimal efficiency and precision.

Transmissions

Intake manifolds

  • Ensure optimal engine efficiency using advanced cutting tools for molds, designed to handle deep cavities with precision and durability.
  • Achieve consistent quality in casted intake manifolds with our machining processes, tailored for dependability and accuracy.
  • Our cross-technology solutions, streamline production and enhance operational efficiency.

Exhaust manifolds

  • Crafted to efficiently recirculate hot gases, exhaust manifolds reduce environmental impact while maintaining optimal engine performance.
  • Choose between mold tooling or direct machining from billet for tailored solutions to meet your specific production needs.
  •  From small batch runs to high-volume output, leverage standalone setups or fully automated systems for seamless efficiency.

Filter housings

  • Realize filter housings feature with intricate designs thanks to our EDM and Milling technologies with precision and efficiency.
  • Our high-quality tooling boosts production processes, offering speed and consistency to tackle even the most complex requirements.
  • From standalone setups to fully automated, cross-technology systems, our solutions adapt to your production scale

Cylinder blocks

  • Tackle the unique challenges of machining cylinder blocks for high-performance powertrains equipped with advanced sensors and variable settings, ensuring top efficiency.

  • Whether you need precision for small batch production or high-volume manufacturing, our technology delivers flawless results.

  • Achieve precision tolerances of 0.05 mm to an exceptional 0.025 mm, ensuring every part meets the highest standards.

Cylinder heads

  • Master machining complex cylinder heads with single and double overhead cam designs with precision, even with the most intricate structures.
  • Achieve faster time-to-market with streamlined processes, enabling rapid prototyping and full-scale production.
  • Deliver flawless results of valve seats with a perfect blue match of <5μm for exceptional performance and reliability.

Drive modules and housings

  • Achieve exceptional accuracy with transmission drive components, crafted from billet to final parts with tolerances as tight as 0.025 mm, ensuring flawless performance.
  • Our advanced machining processes deliver reliable quality across batches, maintaining performance standards for every component.
  • Bring innovative designs to market faster with streamlined new product development, minimizing lead times while maximizing efficiency.

Gears

Automotive powertrains are evolving with diverse gear drive systems. The shift to hybrid, battery, and hydrogen technologies demands ultra-precise manufacturing and low noise levels, posing challenges for suppliers. GF MS solutions integrate advanced EDM, Milling, and System 3R tooling for unmatched precision, stability, and productivity.

  • Achieve top-tier gear tooling milled directly on hard materials, meeting the highest DIN standards and equivalents.
  • Ensure precision in gear tooling for both hot and cold forging at micron levels with our advanced EDM machines.
  • Boost productivity and agility with System 3R tooling, adaptable to a wide range of processes.
  • Run unattended graphite tooling efficiently with our pallet magazine, seamlessly integrated with Milling and EDM machines.

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