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Equipment and spare partsBrowse manufacturers Search by manufacturerWe supply EMAG ECM GmbH machines for electrochemical machining: deburring, drilling, inner profiling and precise shaping of blisks, turbine blades and dies. Each machine can be configured with an electrolyte system, tooling and spare parts.
Entry model of the platform: the machining area, control cabinet and electrolyte management system sit on a single frame. We match the machining module, generator and electrolyte-side units to your process.
Modular machine with manual or semi-automatic loading, ready for robots and gantry loaders. We help select the module, generator and units for your process.
Machine for precise shaping of complex surfaces in hard-to-cut alloys, for example dies. Mineralit base, backlash-free oscillator, Siemens Sinumerik 840D sl control.
Compact PECM machine for turbine blades: two oscillators work from opposite sides. No expensive milling tools, no thermal influence on the part, post-processing practically eliminated.
PECM machine for blisks, the integrated blade-and-disk parts made of nickel-based superalloys. Contactless, fast metal removal: the workpiece is the anode, the tool the cathode.
A separate machine unit for supply, filtration and control of the solution. We select filters, monitoring and dosing components by machine model and electrolyte parameters.
The electrical and mechanical core of PECM: scalable generators, pulse mode, oscillator and CNC. We identify the unit from the nameplate and machine number.
The cathode defines the part geometry and shows almost no wear. Tooling is made for a specific part: deburring, drilling, inner forming, barrel rifling.
Contactless burr removal in hard-to-reach areas: undercuts, pockets and intersecting internal bores. The tool does not wear and no secondary burr is created.
For very hard materials and parts with cavities, where cutting is limited by tool load. No burrs or distortion, so a separate deburring step is not needed.
Electrochemical forming of rifling in short and long barrels: standard, progressive and polygonal. The process is faster than the frequently used hammering, with lower investment.
Electrochemical machining is based on electrolysis: the tool is the cathode, the workpiece the anode, and an aqueous electrolyte flows between them. Metal dissolves without contact, heat or mechanical stress, and the removed material precipitates from the solution as metal hydroxide. Machining works regardless of the structural condition of the metal: soft and hard materials, including exotic alloys, are machined alike. Cathode wear is minimal, and the manufacturer quotes surface roughness down to Ra 0.05. In PECM the gap between workpiece and tool is minimal, the electrolyte is renewed by an oscillating movement, and current is supplied in pulses. This gives high contour reproducibility on complex 3D parts.
The technology serves aviation, automotive, energy, medical, defence, e-bike and truck manufacturing. Typical tasks: blisks and turbine blades, dies, fuel injection nozzles, pistons, camshafts, flanges and rotor shafts. Almost all metals can be machined, especially high-alloy nickel and titanium alloys and hardened materials, where cutting runs into tool wear or needs a separate deburring step afterwards. A separate task group is deburring of parts with undercuts, pockets and intersecting bores.
For a quotation, send a drawing or sketch of the part, material and hardness, batch size, required accuracy and roughness, and whether automation is needed. PI or PS are usually considered for project starts and small series, PTS 2500 for complex 3D surfaces, PO 100 SF for turbine blades and PO 900 BF for blisks. The manufacturer confirms the final configuration, modules and generator against your data. Also state what floor space and power supply are available and whether there is a line the machine must fit into.
EMAG ECM GmbH in Heubach is the electrochemical machining technology center within the EMAG Group. It offers complete solutions, developments, prototype production and consulting, and integrates deburring into the overall process stream. Its technologists develop the process for a specific part, so a sample or drawing is worth attaching to the first request. A machine can be extended with an electrolyte management system, cathode tooling, an automation interface and spare parts for its units.
PS and PI machines are designed to work with robots and gantry loaders: they have software and hardware interfaces, and the options include an automation interface, IoT Ready and an automatic machining-area door. The modular concept lets you start with one station and later add pre-washing, a second ECM station and final treatment, without buying the whole line at the outset.
The process is controlled by time, distance or ldt. The machine monitors electrolyte conductivity, temperature and pH, and the options add fast short-circuit shutdown and automatic cathode cleaning. For multi-nest tooling, pressure and flow monitoring per nest and single-cathode monitoring are available, so a defect on one part does not go unnoticed.
The machining area is built from modules: deburring for an ECM tool, sinking with a Z axis for accurate sinking, oscillation with a Z axis and superimposed oscillation for PECM, and rifling with Z and C axes for internal profiles. Every module except deburring stands on a Mineralit polymer concrete base, which the manufacturer calls eight times more resistant to vibration than grey cast iron. The machine can grow with output by adding washing stations, a second ECM station and automation. One electrolyte management system with a chamber filter press can serve several machining modules; the electrolyte is a NaNO₃ or NaCl solution.
Electrochemical machining forms internal chambers and galleries without burrs or tool marks and without changing the material structure. Example: internal geometry and chamfers of fuel injection nozzles made of high-strength materials. For barrels the manufacturer offers a rifling module for 2 or 8 barrels at once and the PO 3000 IP machine: standard, progressive and polygonal rifling is produced faster than by hammering and with lower investment.
The EMAG Group turning, grinding, gear-cutting and laser machines are described on the page EMAG machines.
We supply equipment on request and do not represent EMAG. The manufacturer publishes no price list or part-number catalogue; configuration, lead time and price are confirmed when the request is quoted.
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