Cutting-tool manufacturer Mapal opened its Fountain Inn, South Carolina plant in 2013 to complement the company’s existing US headquarters in Port Huron, Michigan, as production manager John Schuck recalls: “In 2013, we were sweeping the floors and waiting for the first machines to arrive, one of which was a Vollmer QWD750H wire-erosion machine with a 12-station tool loader. Our immediate growth noted an additional two QWD750H machines arriving in spring 2015.

“From day-one, our ambition and plan for this facility was to run ‘lean and unmanned’ production wherever possible, and the 12-station Vollmer QWD750H wire-erosion machines have supported this philosophy,” he adds.
As the company ramped-up production, it exponentially increased its investment in wire-erosion technology. For instance, Mapal acquired more Vollmer machines in 2018. Succeeding the Vollmer QWD series as the next-generation technology, Mapal took delivery of two new Vpulse500 machines in March 2018.
“We were really pleased with the performance of the QWD750H models, but the new Vpulse500 takes it to a new level,” says Schuck. “Vpulse500 machines incorporate a new erosion generator that is far more efficient than the QWD models. The new erosion generator and the new control format are optimising our productivity, giving us 25-30% cycle time reductions over the previous machines, while generating improved surface and edge finishes. Furthermore, the CNC control and software has been enhanced for greater ease-of-use and operator friendliness.
“No doubt more Vollmer machines will follow as we continue to grow,” he adds. “From a staff perspective, part of our growth trajectory will see us start an apprenticeship programme this year and what better environment for apprentices to learn than in a new factory with state-of-the-art machine tool technology from Vollmer.”
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