Production Systems for Functional, Thermally Coated Surfaces
Thermal Surface Technology combines coating technology, automation and quality assurance to create stable, measurable and production-ready processes.
We develop customized coating machines and production systems for highly stressed components. At the core of our Thermal Surface Technology product line are two key system families: ACCS for thermally coated cylinder bore surfaces and ADCS for thermally coated, low-emission brake discs.
Both system families combine coating technology, special-purpose machinery, automation, optical inspection, measurement technology and process data integration into an integrated end-to-end system solution. This enables reproducible coating results, stable series-production processes and reliable quality data – from initial process validation to high-volume production.
At our in-house Coating Tech Center, we develop and validate coating processes, produce prototypes and support small-batch production. Process trials, sample components, measurement results and process data provide a reliable basis for decision-making and subsequent industrialization.
ACCS – Advanced Cylinder Coating System
Highly efficient production systems for thermally coated cylinder bore surfaces
The Advanced Cylinder Coating System (ACCS) is our system family for the thermal coating of cylinder bore surfaces. Designed for robust, reliable and reproducible series production, the systems combine thermal coating, component handling, inline inspection and data-driven process optimization in an integrated end-to-end solution.
Depending on the component, substrate material, coating requirements and production targets, wire- or powder-based thermal spraying processes can be used. Thin, durable thermal coatings help reduce friction and oil consumption, improve heat transfer and create wear-resistant cylinder bore surfaces for modern powertrain applications.
Integrated quality assurance plays a key role throughout the process. Inspection and measurement systems detect cylinder, roughening and coating defects, measure relevant surface characteristics and provide reliable quality data for stable series-production processes and closed-loop process optimization.
ACCS Systems
What you should now about them
System modules within ACCS
- TWS – Thermal Wire Sprayer: Plasma coating center for cylinder running surfaces featuring RSW technology (Rotating Single Wire) and an integrated Cylinder Inspector.
- TPS – Thermal Powder Sprayer: Plasma coating center for cylinder running surfaces featuring APS technology (Atmospheric Plasma Spraying) and an integrated Cylinder Inspector.
- CI – Cylinder Inspector: Inline measurement system for detecting cylinder, roughening and coating defects, as well as measuring relevant surface characteristics.
- CO – Coating Optimizer: Closed-loop system for reliably controlling the machining allowance after coating, fully integrable into TWS and TPS systems.
Your benefits with ACCS
- Reliable production of thermally coated cylinder bore surfaces at high volumes
- Flexible selection of wire- or powder-based thermal spraying processes, depending on the application
- Integrated inline inspection for transparent and reliable quality data
- Data-driven process optimization and closed-loop control
- End-to-end system engineering – from the coating process to the automated production system
ADCS – Advanced Disc Coating System
Production systems for thermally coated, low-emission brake discs
ADCS enables the scalable production of brake discs with durable wear- and corrosion-resistant coatings. High-speed laser cladding for carbide-coated brake discs, combined with integrated inspection systems, ensures reproducible coating results – from prototypes and small batches to high-volume production. The Disc Inspector and Wear Marker enhance the system with precise inspection, documentation and wear indicators.
ADCS Systems
What you should know about them
System modules within ADCS
- LC – Laser Cladding: Prototype and small-batch production center for carbide coated brake discs with integrated Disc Inspector using High-Speed Laser Cladding.
- LC-HV – Laser Cladding High Volume: High-volume production center for carbide coated brake discs with integrated In-Process Disc Inspector using High-Speed Laser Cladding.
- DI – Disc Inspector: Off-process measuring device for defect detection and measuring relevant surface characteristics on brake discs.
- WM – Wear Marker: Flexible ultrashort-pulse laser engraving system for marking and measuring wear indicators and logos on coated brake discs.
Your benefits with ADCS
- Thermal coating solutions for wear- and corrosion-protected brake discs
- Scalable system concepts from prototypes and small batches to high-volume production
- Integrated and process-related inspection for stable quality and transparent data
- Expandable system solution with Laser Cladding, Disc Inspector and Wear Marker
- Support in the development, industrialization and series process validation of low-emission brake discs
Advanced Special Coating Systems
Complementary systems and services
In addition to ACCS and ADCS, we realize flexible special-purpose coating systems for further components, technologies and production environments. These include, for example, Flexible Coating Cells for various components such as turbine components, pipes, shafts or customized special applications.
Add-ons für Advanced Coating Systems
Supplementary modules such as Automation System, Line Control, Data Handling, Traceability or automatic Powder Refill Systems can be integrated into modern production lines and support stable, transparent and efficient coating processes.
Why Sturm Surface Technology is your ideal partner for thermal surface technology
ACCS and ADCS as clearly defined product platforms
Our core systems combine coating, automation, inspection and process data in integrated production solutions for cylinder running surfaces and brake discs.
From initial process trials to high-volume production
We support our customers from the first coating trial through prototyping and process validation to fully automated series production systems.
Integrated quality assurance
The Cylinder Inspector, Disc Inspector and Coating Optimizer provide transparent quality data, enable early defect detection and support stable process control.
Modular and customized system concepts
Systems and add-ons can be tailored to specific components, production volumes, levels of automation, quality targets and existing production structures.
Combined expertise within the Sonplas Group
As a center of expertise within the Sonplas Group, we combine surface technology with special-purpose machinery, automation, assembly, testing, software and service.
Lifecycle responsibility
Engineering, commissioning, production support, service, retrofitting and system modernization are considered as part of an integrated lifecycle approach.
Interested? Let's talk about your project!
Contact us without obligation and tell us about your requirements. Together, we will develop the right solution – technically well thought out and precisely tailored to your needs.
