TOOLING MANUFACTURER MAPAL LAYS THE FOUNDATION FOR GREATER SPEED

Industry Industrial manufacturing around the world is undergoing rapid change. Geopolitical tensions, structural shifts in key industries, a weak economic outlook in Europe and new challenges in global supply chains are changing the way companies do business.

At MAPAL, several of these developments are coming together at the same time. The company group has deep roots in Germany and Europe, holds a strong position in the automotive industry, and supports its customers through long-term investment projects. These are precisely the areas that have come under significant pressure in recent years.

“We’re not experiencing a temporary market slowdown, but rather profound changes across many of the markets that are important to us,” explains Dr Jochen Kress (pictured), president of the MAPAL Group. “These changes affect economic conditions, technological developments and geopolitical influences alike.”

Since mid-2025, growing uncertainty in global raw material markets has added to the challenges, driven in particular by export restrictions and rising prices for carbide pre-products.

“Developments in the raw material markets highlight just how important resilient supply chains and long-term partnerships are,” says Kress. “Reliable supply is becoming an even more important issue for the industry as a whole. The MAPAL Group is currently well positioned in this regard and remains a reliable supplier.”

Against the backdrop of these market changes, the 2025 financial year developed in line with expectations. The MAPAL Group generated revenue of €514m, around 7% below the previous year’s figure of €551m. Performance varied across regions. While economic growth in Europe and China remained subdued and the automotive industry continued to be shaped by far-reaching changes, individual markets in North and South America, as well as Asia, proved more resilient.

By the end of 2025, the MAPAL Group employed around 4500 people worldwide. The adjustment of the workforce structure was made in response to market conditions. In doing so, the family-owned company focused on socially responsible solutions and long-term decisions.

“The environment was challenging and remains so. That makes it all the more important to focus on things we can influence ourselves. That’s exactly what we’ve done, driving MAPAL forward with determination.”

With the merger of its German entities, MAPAL completed the largest organisational project in the company’s history. At the same time, the group was realigned as a process-driven organisation. Standardised workflows, clearly defined responsibilities and structures, and end-to-end processes provide the foundation for more transparency, higher efficiency and, most of all, greater speed.

“Many of these changes initially took place behind the scenes and were not visible to the outside,” states Kress. “Transformation initiatives of this scale require time, consistency and a willingness to challenge established ways of working. For us, 2025 was mainly a year of implementation.”

The intensive work on structures and processes is beginning to deliver results. The organisation is gaining speed, and customer requirements are being implemented more efficiently.

MAPAL reached another milestone in spring 2026 in achieving TISAX certification at Assessment Level 3. The certification confirms the company’s high standards in information security and meets the requirements of demanding customers, particularly in the automotive industry. At the same time, it reflects the ongoing development of processes, structures and the organisation as part of the company’s transformation journey.

Alongside its organisational progress, the strategic direction MAPAL has pursued in recent years is also proving successful in key market segments. This is particularly evident in the aerospace sector. Over the past two years, MAPAL has achieved double-digit growth in its aerospace business, outperforming the market as a whole. As a result, MAPAL has further strengthened its position in this technologically demanding segment and is benefiting from strong global demand in the aerospace industry.

MAPAL also remains committed to its long-term investment strategy. In the 2025 financial year, the MAPAL Group invested around €25m in its sites, production capabilities, digitalisation and future technologies. The company expects to reach a similar level of investment by the end of 2026 financial year.

Following its 75th anniversary year, MAPAL continues to combine the strengths of a long-established family-owned company with a clear focus on meeting the demands of future markets.

Despite its extensive transformation projects, innovation remained a central focus of the company’s activities. In 2025, for example, MAPAL introduced the NeoMill-16-Finish indexable insert milling cutter, a new milling system for cost-efficient semi-finishing and finishing. The new standardised chip-breaking geometries for fine-boring inserts increase process reliability and deliver productivity gains. These examples are representative of the company’s ongoing commitment to innovation. The goal remains to help customers make their manufacturing operations more productive and efficient through high-performance tools, intelligent processes and comprehensive system solutions.

Alongside its established market segments, MAPAL is also keeping a close eye on emerging industrial growth areas. These include applications in the defence sector as well as industrial applications arising from new requirements in security, infrastructure and energy supply.

The company is deliberately taking a long-term approach in these areas. New markets and technologies are evaluated according to clearly defined criteria: they must align with the company’s technological strengths in precision machining, offer sufficient market scale and production volumes, and demonstrate long-term potential.

“We closely monitor new developments and stay technologically connected to the topics that matter,” says Kress. “At the same time, we invest selectively in areas where we see sustainable market opportunities and can create real value for our customers. Not every trend automatically becomes a market.”

Market conditions will remain challenging throughout the 2026 financial year. Economic growth in Europe continues to be subdued, while geopolitical uncertainty, changes in global supply chains and developments in raw material markets continue to influence the business environment. At the same time, investments in aerospace, infrastructure and other future-focused technologies are creating new opportunities.

For the 2026 financial year, the company expects revenue to remain at a similar level to the previous year. Nevertheless, MAPAL believes it has created the conditions to respond to market opportunities more quickly and decisively in the future.

“The challenges in our markets are not going away anytime soon,” he concludes. “What matters is how quickly and decisively we respond to change. That’s exactly why we’ve created the right conditions: we’re becoming faster, strengthening our ability to get things done. And we’re sharpening our focus on identifying opportunities earlier, making decisions more quickly, and bringing solutions to our customers faster.”

More information www.mapal.com

Ceratizit heralds MACH 2026 as its best of all time

Ceratizit UK & Ireland has reported its most successful MACH exhibition to date. The company’s stand attracted strong interest throughout the week, with manufacturers visiting to explore the company’s latest cutting tool, tooling management and work-holding technologies.

The exhibition showcased Ceratizit’s machining portfolio across milling, turning, drilling, threading, grooving and parting applications, supported by demonstrations from the company’s UK Technical Centre. Among the standout attractions was the CTC5240 titanium indexable milling system display, developed in collaboration with the University of Sheffield AMRC, Heller Machine Tools and Siemens NX.

Designed specifically for difficult-to-machine materials including titanium, Inconel, Hastelloy and Waspaloy, the CTC5240 grade generated significant attention from engineers attending the exhibition. Ceratizit demonstrated how its proprietary coating technology improves heat resistance, chip formation and tool life in demanding titanium machining operations.

A key highlight was a live machining demonstration using the new RADX porcupine cutter paired with SXHU 120408ER-F41 CTC5240 inserts during a full-slot milling operation in TiAl6V4 titanium alloy. The application achieved a material removal rate of 318.78 cm³/min while benefiting from eight usable cutting edges per insert, creating a highly competitive solution for heavy-duty titanium roughing applications.

The Ceratizit UK & Ireland engineering team is currently working with manufacturers to implement productivity and cost-saving improvements identified during MACH.

The company also continued its long-running MACH charity initiative, with visitors entered into a prize draw to win a Hope HB160 mountain bike in exchange for donations to the British Heart Foundation and Cancer Research UK. Over the past 16 years, the initiative has raised more than £100,000 for the two charities.

More information www.ceratizit.com

Live turning insight for safer, smarter automation

Sandvik Coromant has launched CoroTurn Plus, a sensor-equipped turning adaptor designed to provide real-time process visibility, improve machining stability and support higher levels of automation in turning applications.

The new system enables manufacturers to monitor cutting forces, vibration, chatter and in-cut status in real time, helping operators identify process instability, material variation and tool wear before they impact productivity or component quality. By making machining conditions visible during the cut, CoroTurn Plus is intended to improve process security, reduce waste and support more consistent production.

CoroTurn Plus combines sensor-integrated tooling with two levels of digital capability. When used with CoroPlus Viewer, the system provides live visualisation of machining data via a PC or tablet, allowing operators to track performance trends, receive audible alerts when limits are exceeded and review deviations for faster root-cause analysis. The platform also enables teams to identify insert wear trends more accurately, helping optimise tool life while avoiding unplanned downtime.

For higher levels of automation, CoroTurn Plus integrates with CoroPlus Connected and the machine’s NC control system. Users can define vibration, chatter and load limits directly in the software or NC code. If those limits are exceeded, the machine can automatically trigger protective actions such as stopping, retracting or resuming the process to protect tooling, components and equipment.

According to Åke Åxner, global project manager for machine integration, the technology transforms hidden cutting behaviour into clear process signals, enabling manufacturers to detect instability and react immediately. Product manager Leland Bailey adds that sensor-based tooling provides a practical route towards more advanced automation by converting machining data into safe, machine-controlled actions.

By combining live process monitoring with machine-level integration, CoroTurn Plus aims to support unmanned machining, improve machine utilisation and deliver greater consistency across turning operations.

More information www.sandvik.coromant.com

Rainford Precision: “MACH gets better every time”

“Every MACH exhibition keeps improving on its predecessor,” said Miles Evans, managing director of Rainford Precision, following a successful week at the show.

As a specialist in micro machining, Rainford Precision attended the exhibition to showcase its portfolio of tooling solutions for small-part machining, hard material applications and composite machining. Representing globally recognised brands including Union Tool, Louis Bélet, IWATA, Hufschmied, Delmeco, HOBE and Osawa, the company attracted strong interest.

According to Rainford, many visitors arrived at the stand after struggling to find tooling elsewhere at the exhibition capable of meeting the precision, dimensional accuracy and material demands required by their applications. The company’s range of micro-machining solutions demonstrated capabilities for producing extremely small features and drilling difficult materials beyond the scope of conventional tooling systems.

Particular interest was shown in Union Tool’s HGLB, HWLB, HWLB-S and CWLB series of two-flute ball-nose end mills for machining materials up to 60 HRc. With radii from 0.05 to 3 mm, diameter tolerances of 0/-0.006 mm and ball radius accuracy of ±0.002 mm, the tooling highlighted the level of precision increasingly demanded across industry.

Rainford also introduced the Louis Bélet Excalibur series at MACH for the first time. Featuring inserts brazed to carbide bodies with laser-machined helical geometries, the tooling offers significantly extended tool life compared with solid carbide alternatives, while supporting diameters as small as 0.1 mm.

For manufacturers in aerospace, motorsport, mould and die, and defence, IWATA Tool’s deep-hole drilling technology also attracted strong attention, particularly the ALT-coated three-flute drills capable of achieving H7 tolerances in materials up to 72 HRc.

Evans concluded: “MACH consistently generates a high volume of high-quality leads from manufacturers new to Rainford Precision, and we’re already converting enquiries from the exhibition into new business.”

More information www.rainfordprecision.com

Rising carbide prices: When cermet makes sense

As pressure on global raw material supply chains continues to intensify, manufacturers are increasingly reassessing how cutting tool materials are used throughout the machining process. According to Tungaloy Corporation, carbide remains essential for heavy roughing applications, but its use is not always technically necessary in finishing operations where cutting loads are significantly lower.

In many finishing applications, the focus shifts away from maximum toughness towards process stability, surface quality and efficient material usage. Under these conditions, cermet provides a practical and engineered alternative capable of reducing carbide consumption without compromising machining performance.

Finishing operations typically involve shallow depths of cut, high cutting speeds and continuous or lightly interrupted machining conditions. These are precisely the environments where cermet performs most effectively. Developed from ceramic and metallic components, cermet grades are specifically engineered to deliver high wear resistance, predictable tool life and excellent surface finish in stable machining conditions.

Tungaloy’s cermet range is designed for finishing and light semi-finishing applications in steels and alloy steels. The NS9530 grade provides a balanced combination of wear resistance and toughness for stable finishing operations, while GT9530 is optimised for precision finishing applications where surface quality is critical. The AT9530 grade has been developed specifically for alloy steels, delivering consistent machining performance in continuous cutting conditions.

Rather than attempting to replace carbide universally, Tungaloy emphasises that cermet should be viewed as part of a smarter material allocation strategy. When matched correctly to the application, cermet can help manufacturers reduce dependence on carbide resources, maintain stable productivity and improve overall process efficiency.

More information www.tungaloy.com