The Company.

MAPAL Präzisionswerkzeuge Dr. Kress KG – a medium-sized family company –

has been for decades one of the leading suppliers of precision tools for the metal
machining industry. As a supplier MAPAL provides support for its customers from
project planning for individual processes to Tool Management.

MAPAL-E-01-020-0507-WD Printed in Germany. Right of technical modifications reserved!

www.mapal.com
 The Company.

MAPAL Präzisionswerkzeuge Dr. Kress KG – a medium-sized family company –

has been for decades one of the leading suppliers of precision tools for the metal
machining industry. As a supplier MAPAL provides support for its customers from
project planning for individual processes to Tool Management.

MAPAL-E-01-020-0507-WD Printed in Germany. Right of technical modifications reserved!

www.mapal.com
MAPAL Dr. Kress KG in Aalen
The MAPAL Group headquarters
With the establishment of MAPAL by
Dr. Georg Kress in 1950 in Aalen, the
foundation stone was laid for the com-
pany which now operates worldwide.
The meteoric success of the company
began with the successful introduction
of single blade reamers with guide
pads (the MAPAL principle).
Based on this tradition the headquar-
ters in Aalen is now the main produc-
tion site for reamers and fine boring
tools with guide pads. With more
than 1.100 employees, multi-bladed
reamers, clamping systems and setting
devices are also produced in Aalen.
In addition to the general manage-
ment, the central functions are also
located in the headquarters as coor-
dination points for the whole MAPAL
Group. Along with the development
and marketing centre, the new cus-
tomer services centre is also part of the
MAPAL Group central functions. In the
production area MAPAL Aalen supplies
the manufacturing daughter com-
panies with tool bodies and numerous
additional parts. The headquarters
is also the venue for the wide variety
of MAPAL’s general and advanced trai-
ning events. This includes technical
seminars and technical orientation as MAPAL Präzisionswerkzeuge
well as offer training sessions, both for Dr. Kress KG
customers and for employees from all P.O. Box 1520
MAPAL’s daughter companies and D-73405 Aalen
agents. Telephone +49 (73 61) 5 85-0
Fax +49 (73 61) 5 85-1 50
info@de.mapal.com
www.mapal.com
MAPAL Dr. Kress KG in Aalen
The MAPAL Group headquarters
With the establishment of MAPAL by
Dr. Georg Kress in 1950 in Aalen, the
foundation stone was laid for the com-
pany which now operates worldwide.
The meteoric success of the company
began with the successful introduction
of single blade reamers with guide
pads (the MAPAL principle).
Based on this tradition the headquar-
ters in Aalen is now the main produc-
tion site for reamers and fine boring
tools with guide pads. With more
than 1.100 employees, multi-bladed
reamers, clamping systems and setting
devices are also produced in Aalen.
In addition to the general manage-
ment, the central functions are also
located in the headquarters as coor-
dination points for the whole MAPAL
Group. Along with the development
and marketing centre, the new cus-
tomer services centre is also part of the
MAPAL Group central functions. In the
production area MAPAL Aalen supplies
the manufacturing daughter com-
panies with tool bodies and numerous
additional parts. The headquarters
is also the venue for the wide variety
of MAPAL’s general and advanced trai-
ning events. This includes technical
seminars and technical orientation as MAPAL Präzisionswerkzeuge
well as offer training sessions, both for Dr. Kress KG
customers and for employees from all P.O. Box 1520
MAPAL’s daughter companies and D-73405 Aalen
agents. Telephone +49 (73 61) 5 85-0
Fax +49 (73 61) 5 85-1 50
info@de.mapal.com
www.mapal.com
MAPAL Sites in Germany

The MAPAL Group in Germany

In addition to its headquarters in

Aalen, there are four other production
sites within the MAPAL Group in
Germany:

MAPAL WWS GmbH in Pforzheim

The WWS company was set up in
Pforzheim in 1980 and has been part
of the MAPAL Group since 1994. To-
day MAPAL WWS GmbH is the leading
manufacturer of tools with PCD blades.
Combination tools for gun boring and
circular interpolation milling are one
of their highlights.

With the foundation of MAPAL

ISOTOOL GmbH in Sinsheim in 1997
MAPAL extended its range of products MAPAL ISOTOOL GmbH in Sinsheim
with generating slide tools and slide
tools, together with special tools with
ISO elements.

MILLER GmbH, founded in 1991 has

been part of the MAPAL Group since
2003. MILLER produces precision tools
for boring, milling, counterboring and
reaming in solid carbide and in Cermet.

Rudolf Strom GmbH in Vaihingen/Enz

has been part of the MAPAL Group MILLER GmbH in Altenstadt
since 1999 and produces special tools
with ISO elements for a wide variety of
operations.

Rudolf Strom GmbH in Vaihingen/Enz

MAPAL worldwide

Quality, close customer contact and early identification of the The MAPAL Group in figures:
developments and demands of the market are MAPAL's primary
objectives. More than 2.500 people employed by the MAPAL more than 2.500 employees
Group work out perfect solutions every day for customers' ma- 20 subsidiaries
chining tasks. Because of the ongoing general and advanced 17 production sites
training of personnel and the constant exchange of experience, 30 offices providing service and
MAPAL ensures high technical standards worldwide and guar- advice in very continent
antees MAPAL's legendary quality.

MAPAL Group sites

In Europe In Asia
Germany China
MAPAL Dr. Kress KG in Aalen MAPAL China Ltd. in Shanghai
MAPAL WWS GmbH in Pforzheim Japan
MAPAL ISOTOOL GmbH in Sinsheim MAPAL KK in Tokyo
MILLER GmbH in Altenstadt Korea
Rudolf Strom GmbH in Vaihingen/Enz MAPAL HTT Co. Ltd. in Kyunggi-Do
France MAPAL TET Office Asia in Ulsan
MAPAL France in Le Chambon Feugerolles India
Great Britain MAPAL INDIA Private Ltd. in Bangalore
MAPAL Ltd. in Rugby Singapore
Italy MAPAL Asia TET Office in Singapore
MAPAL Italia S.R.L. in Gessate/MI Taiwan
Poland MAPAL Precision Tool System Co. Ltd. in Tainan
MAPAL Narzędzia Precyzyjne Spółka z o.o.
in Poznań In America
Czech Republic USA
MAPAL CZ s.r.o. in Dlouhá Lhota MAPAL Inc. in Port Huron MI
Mexico
MAPAL FRHENOSA in San Pedro Garza Garcia
Brasil
MAPAL do BRASIL Ferramentas de Precisão Ltda. in Ibirité
MAPAL Qualifer Ltda. in Belo Horizonte
MAPAL – wherever the customer is, we are there.
MAPAL
Reliably innovative
10 11
“How can one define a company, an extremely lively organism, which has developed further and further
for more than 50 years and with which so many people – customers throughout the world, employees
and suppliers – are so closely linked, in a brochure with just a few pages?
We have dared to do so because we know that in our Company it comes down to just a few important
principles.
We want to be close to our customers, be and remain in dialogue with them, think and act for them. Find
and form a team which will feel permanently committed to this idea – at all levels of the company.
Quality, reliability and innovative strength are also factors which play a decisive role in the company
– day after day.
Using brief comments throughout I hope to illuminate the various aspects of our Company and clarify
what is important to us – now and in the future.“

Dr Dieter Kress
Chairman & Managing Director
Branches and products
Perfect dialogue
14 15

“The customers expect us to provide them with a comprehensive,

reliable and innovative programme from our range of competences –
at all the principal production sites in the world. This is what we do.
This is how MAPAL is set up.“

Whether you are travelling in a high performance car with good fuel economy,
safely lifting heavy loads with hydraulics or reading your freshly printed news-
paper, MAPAL will always have been involved.
MAPAL's knowledge and experience of tools is found in almost all areas of
metalworking. Absolute precision and efficiency with maximum production
reliability are required in increasing measure in modern production technolo-
gy. The customers' demands are met by high quality specifications and the
constant development of MAPAL precision tools.
As a competent tool partner, MAPAL
also offers a comprehensive range of
customer services. For MAPAL cus-
tomers, savings in costs start right at
the project planning stage. By using
innovative and reliable tool concepts,
MAPAL's tool experts show the way –
from low-cost production of a compo-
nent to saving costly additional opera-
tions. Tool Management with MAPAL
offers the right tool, at the right time,
at the right place, at an economic price
and guarantees profitable production.
16 17
Reaming and
fine boring tools
For 50 years, using reamers and fine
boring tools with guide pads, MAPAL
has set the highest quality standards
for cutting with geometrically defined
blades. The MAPAL principle guaran-
tees the dimensional stability and form
of the bore within just a few microns,
reliably and economically. While the
guide pads are specifically designed
for their task (guiding the tool in the
bore), the blades, which are precisely
matched to the machining task in cut-
ting material and cutting lead, deal
with cutting the material. Whether
cast iron, steel or other materials,
MAPAL tools always achieve remarka-
ble results.
Just as MAPAL has successfully intro-
duced the idea of single-blade reamers
into the industry, significant advan-
tages have also been offered by the
new High Performance Reamers. Using
the HFS® Head Fitting System and its
high level of accuracy, this tool con-
cept meets the requirements of many
customers for high quality and easy
tool handling. One way heads also
ensure a high level of economy for this
completely new system. For special
tools the successful combination of
various cutting systems brings com-
pletely new forms of rational produc-
tion methods.
18 19
PCD tools
In the area of tools with PCD blades
MAPAL has emerged as one of the prin-
cipal manufacturers in the last ten
years. The programme for this product
line includes precision gun boring
tools, circular interpolation milling
tools and end mills, and a successful
face milling head system with replace-
able milling cartridges.
Modern and high-precision clamping
systems combined with precision
grinding quality for maximum dimen-
sional stability and concentricity open
up numerous options for fixed and
brazed MAPAL PCD tools, not only
in HSC operations.
Generating slide tools and special tools
with ISO elements
With the precision machining of
bores as a starting point, MAPAL
special tools now offer complete
solutions for the machining of
cubic parts. MAPAL deals inten-
sively with production options
which are made possible by the
use of slide tools and generating
slide tools. For these technically
demanding solutions, generating
slide tools, which can be used on
machining centres at little cost
or no cost at all, have been par-
ticularly progressive develop-
ments. In the area of special
tools with ISO elements, our
specialists' tremendous experi-
ence and numerous innovative
ideas produce extremely suc-
cessful tool concepts for gun
boring and milling.
20 21

Solid carbide tools

To provide a complete range of compe-
tences in bore machining, MAPAL also
offers a product line of excellent spe-
cial and standard tools in solid carbide.
This range from simple drills to the
latest high performance drill. Tools
which achieve reaming quality in a
single pass are a particular highlight
in this product line.
Coatings developed especially for
boring and the use of super cutting
materials PCD and PCBN are further
features which increase the perfor-
mance of MAPAL solid carbide tools.

Clamping systems
HSK and HFS® are key terms when it
comes to clamping tools accurately
and safely. Modern production tech-
niques are also significantly influenced
by both systems. The HFS® Head Fitting
System with replaceable heads is a
completely new development at
MAPAL and opens up new perspectives
for modern production technology in
terms of easy handling, high change-
over and concentricity accuracy and
versatile use.

Setting devices
The precision of surface, form and di-
mension which can be achieved with
MAPAL tools with guide pads are at the
top end of what is feasible with geo-
metrically defined blades. To manu-
facture to micro-precision reliably and
repeatedly with every new blade and
every new tool, MAPAL offers special
tool setting devices which make set-
ting easy. Mechanical and electronic
versions are included in the supply
programme.
Customer services
With CTS® – Complete Tooling Services
– MAPAL has gained a leading position
in the area of customer service. Pro-
duction planning, maintenance, man-
agement and optimisation: the service
package takes MAPAL's experience and
competence from the process design
stage to permanent process optimi-
sation in all customer service areas.
MAPAL CTS® guarantees optimum
results for your special applications –
and at reduced costs. Many years of
intensive and customer-orientated
collaboration make MAPAL a specialist
also in the service area.
Innovation
Realizing the impossible
24 25

“We believe that real innovations provide the thrust for the develop-
ment of a company. But for innovations we must create freedom in our
employees’ thinking and acting. It is only freedom which will lead to
new ways that drive technology forwards.
And: Innovations must be presented to the customers with force,
courage and pace. Only then will they bring the company success.“

Minimal quantity lubrication TOOLTRONIC®

MAPAL was and is decisively involved

in the development of new technolo-
gies. At the MAPAL development cen-
tre experienced specialists deal inten-
sively with subjects such as minimal
quantity lubrication, high speed and
high performance cutting (HSC and
HPC) and the machining of special
materials. Today hardened steels,
sintered materials, CGI or ADI play
an important role in this. MAPAL cus-
tomers profit from this technological
advance with tools which offer greater
economies and quality.
Innovations are a feature of all MAPAL Face milling heads with PCD
products. Many of these innovations and PCBN replaceable cartridges
relate to the solution of tasks with
which our customers confront us
on a daily basis. Often unusual ways
are adopted for this and almost un-
achievable targets reached. In prin-
ciple, the objective is to find new tool
ideas which achieve savings potential
of more than 30 %. A modern range
of machines in MAPAL's development
centre allows trials to be carried out as
closely as possible to how the opera-
tions will run subsequently at the cus-
tomer's works. Hard machining

By working doggedly on new tasks,

but also by making large and small
steps with current problems, MAPAL
innovations repeatedly lead to new
paths and new opportunities in cutting
operations. Examples such as machi-
ning cast iron with PCD, hard machi-
ning with multi-bladed tools or the
development of the HFS® Head Fitting
System demonstrate expertise, a rich-
ness of ideas and creative potential.

HFS® Head Fitting System

with radial clamping
Precision
Absolutely precise
28 29

“Precision is MAPAL's promise to the market and consequently an ongo-

ing and self-evident obligation on our Company. Our customers can rely
on this. And they know it.“

The precision which can be achieved

on the part relates directly to the pre-
cision of the tool. With the diversity
and number of MAPAL's special tools
consistent and thorough quality assur-
ance represents an indispensable and
fundamental principle for the products'
success. The use of modern machining
methods combined with decades of
experience guarantees that the tools
achieve the highest precision.
The high precision of MAPAL tools
reflects directly on the customers' pro-
duction. For finish machining MAPAL
offers interesting tool concepts with
which previously necessary semifinish-
ing operations and even additional
operations, such as grinding or honing,
can be dispensed with entirely. The re-
duction in production costs and the
simultaneous increase or assurance
of machining results under batch pro-
duction conditions is the aim of every
MAPAL tool we offer.
The requirements for circular and
cylindrical form and surface finish
when producing valve bodies for
automatic transmission systems are
less than 4 µm, with additional SPC
limitations. MAPAL tools achieve this
quality thanks to their precision and
the MAPAL principle. In a further
example a critical surface requirement
is achieved when machining a steering
box with a particular cutting lead. The
result lies with a dominant waviness of
WDc at < 0,2 µm. This means that
there is no need for costly additional
machining on the bore.
Reliability
Absolutely dependable
32 33

“If one is constantly in dialogue with customers – as we are – reliability

in all areas and at all levels of the company is an essential maxim for
people’s dealings. How can one otherwise face the customer?“

The provision of process-orientated,

comprehensive and customer-focused
solutions defines the way MAPAL ope-
rates. This includes much more than
manufacturing efficient tools, preci-
sion blades or accurate clamping devi-
ces. Reliable customer services cove-
ring all products are ultimately the
guarantee of their sound and profitable
function. Service is an evermore im-
portant factor in MAPAL's understand-
ing and the capacity which is reserved
for this is suitably large. MAPAL is open
to finding innovative ways when offer-
ing customer services. Considerable
experience in the machining of cubic
parts provides the necessary back-
ground.
Reliable partners and reliable tooling
bring about the appropriately high pro-
cess reliability for today's require-
ments. This means that when they are
fitted onto the spindle, the tools im-
mediately produce the right quality,
the blade cuts for a long and precisely
determined time and the preparation
and tool supply is properly organised.
MAPAL has the right products to offer
for all these factors and as a result pro-
vides reliable production.
The demands set by the customer with
regard to process reliability has a Cpk
value of 1,67. Production reliability
increases as the Cpk value increases.
3 to 4 times the values, for example, is
achieved when machining the cam
shaft bearing bore in cylinder heads.
Diameter tolerances and concentricity
results for the individual journals in
relation to each other are accurately
maintained, both for the cam shaft and
the crank shaft bearing bore, by means
of the guide pads in MAPAL tools.
Sharpening the senses
Dialogue with technology
36 37

“Dialogue with technology – constant, uninhibited and free. For this we

need to win over our younger employees. This is the only way we will
find the new ideas, pioneering solutions, real innovations which the
manufacturing economy needs.“

The people at MAPAL navigate the con-

flicting fields of defining tasks and
applying possible solutions by con-
tinuous dialogue. This dialogue is with
other people but also with technology
itself.
Chip form, wear or the surface of the
part – they all provide information
about possible improvements. And this
technical dialogue is conducted inter-
nationally. All personnel at MAPAL
sites in Europe, America and Asia work
responsibly together with and for tech-
nology within their area of work; by
doing so they contribute to the success
of the MAPAL Group and to the suc-
cessful use of tools by customers –
worldwide.
A prerequisite for qualified personnel
is good general and advanced training.
Today, because developments are
moving even faster, it is important to
recognise this for the old and the
young. It is in acknowledgement of
this that MAPAL guides and challenges
its employees and offers general and
advanced training in the various areas
of work.
There is also dialogue and association
with universities and research insti-
tutes. By commissioned work or
working together on combined pro-
jects, fundamental trends are investi-
gated and solutions worked out to-
gether.
38 39

“We are constantly in dialogue with technology – at all levels of the

company, hour by hour, day by day. This means that opportunities are
explored which present themselves in a wide variety of technical fields
– to the customers' advantage and for constantly optimised and
efficient production processes.“
MAPAL Dr. Kress KG in Aalen
Das Stammhaus der MAPAL Gruppe
Mit der Gründung von MAPAL durch
Dr. Georg Kress im Jahre 1950 in Aalen
wurde der Grundstein für das mittler-
weile weltweit operierende Unterneh-
men gelegt. Mit der erfolgreichen
Einführung der Einschneiden-Reibahle
mit Führungsleisten (MAPAL Prinzip)
begann der rasante Erfolg des Unter-
nehmens.
Aus dieser Tradition heraus ist das
Stammhaus in Aalen heute der bedeu-
tendste Fertigungsstandort für leisten-
geführte Reibahlen und Feinbohrwerk-
zeuge. Mit über 1.100 Mitarbeitern
werden in Aalen auch mehrschneidige
Reibahlen, Spannzeuge und Einstell-
geräte produziert.
Neben dem Sitz der Geschäftsleitung
sind im Stammhaus die Zentralberei-
che als Koordinierungsstellen für die
gesamte MAPAL Gruppe angesiedelt.
Außer dem Entwicklungs- und Marke-
tingzentrum gehört das neue Dienst-
leistungszentrum zu den zentral steu-
ernden Bereichen der MAPAL Gruppe.
In der Fertigung versorgt MAPAL Aalen
die produzierenden Tochterfirmen mit
Werkzeuggrundkörpern und einer Viel-
zahl von Zubehörteilen. Zudem ist das
Stammhaus auch der Ort für die viel-
fältigen Trainings- und Fortbildungs-
aktivitäten. Dazu gehören die unter- MAPAL Präzisionswerkzeuge
schiedlichsten Fachseminare, Tech- Dr. Kress KG
niktrainings und andere Schulungen, Obere Bahnstraße 13
sowohl für Kunden als auch für die D-73431 Aalen
Mitarbeiter aller Tochterfirmen und Telefon +49 (73 61) 5 85-0
Vertretungen von MAPAL. Telefax +49 (73 61) 5 85-1 50
info@de.mapal.com
www.mapal.com
 The Company.

MAPAL Präzisionswerkzeuge Dr. Kress KG – a medium-sized family company –

has been for decades one of the leading suppliers of precision tools for the metal
machining industry. As a supplier MAPAL provides support for its customers from
project planning for individual processes to Tool Management.

MAPAL-E-01-020-0507-WD Printed in Germany. Right of technical modifications reserved!

www.mapal.com