Castolith™ -Frame

The Castolith frame is a custom-engineered, monolithic machine structure cast entirely from a single block of Iron. In one unified casting process, the base frame, side gantry supports, lower enclosure, and integrated coolant and chip tray are formed - with no bolted-on parts or weld seams. 

After casting, the structure is annealed to relieve internal stresses, then precision-machined on all sides. The result is an exceptionally rigid, dimensionally stable frame, purpose-built to handle demanding industrial loads – a concept found nowhere else in this class of machine.

FEM Simulation: Verification of Structural Reserves of the BLOQ4³

To assess the frame stiffness, the Castolith™ frame of the BLOQ4³ was subjected to a finite element analysis (FEM). The objective was not only to validate the structure under operating conditions but especially to evaluate the mechanical reserves under significantly elevated loads.

For this purpose, forces of 1000 N, several times the typical process forces, were applied in the X, Y, and Z directions at the mounting points of the X-portal. Deformations were evaluated relative to the mounting points of the Y linear guides - precisely at the mechanical interface where the frame structure must demonstrate its stiffness.

Simulation Results:

• X direction: 0.008 mm to 0.014 mm

• Y direction: 0.006 mm to 0.012 mm

• Z direction: 0.003 mm to 0.004 mm

Despite these deliberately exaggerated test loads, the Castolith™ frame showed only minimal deformations—a clear indication of its high inherent stiffness and structural robustness.

Conclusion:

The FEM simulation impressively demonstrates that the BLOQ4³ has generous stiffness reserves and remains dimensionally stable even under extreme loads. This provides an ideal foundation for reliable machining processes with high repeatability - even in dynamic applications.