Precisely manufacture high-performance gearbox components

Precision Manufacturing Manufacturing High-Performance Gearbox Components Precisely

2025-06-05 Source: Press release | Translated by AI 2 min Reading Time

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Zoerkler Gears GmbH & Co KG manufactures highly precise gearbox components on the vertical pick-up turning machine VL 6 from Emag. Its multifunctionality not only enhances precision but also reduces lead times.

High-precision machining of a gearbox housing on an Emag VL 6.(Image: Emag) — High-precision machining of a gearbox housing on an Emag VL 6.
(Image: Emag)

Zoerkler looks back on an almost 120-year history and has evolved from a mechanical workshop to an innovation leader in the manufacture of high-performance transmissions. The company today employs around 100 employees, including 8 trainees and 15 highly qualified designers, and specializes in the development, production, and testing of drive systems for high-performance automobiles, helicopters, and airplanes.

The decision for the Emag VL 6 was based on the need to automatically machine heavier components with the highest precision and reliability. Bernhard Wagner, the company's managing director, explains:

Gallery

The impressive helicopter gearbox test stand from Zoerkler.(Image: Emag)

Modern production hall with the vertical pick-up turning machine VL 6 from Emag at Zoerkler.(Image: Emag)

The high quality standards are also reflected in the design of the production hall of Zoerkler in Jois, Austria.(Image: Emag)

Bernhard Wagner, managing partner of Zoerkler Gears GmbH & Co KG.(Image: Emag)

The VL 6 allows us to produce complex parts with excellent dimensional accuracy even with frequent retooling for our small series. This is crucial for our production flexibility and meeting the high quality requirements of our customers from the aerospace and automotive industries.

Bernhard Wagner, Managing Director, Zoerkler Gears GmbH & Co KG

The integrated hard turning and milling functions of the machine are particularly noteworthy. This multifunctionality enables Zoerkler to perform demanding machining steps in a single setup, which significantly enhances precision and reduces lead times. Another advantage of the VL 6 is its highly advanced automation system.

We can often run the machine autonomously in the second and third shifts, which significantly increases our productivity.

Bernhard Wagner, Managing Director, Zoerkler Gears GmbH & Co KG

The combination of reliable automation and consistent precision enables efficient production around the clock without compromising on quality.

Not Only Manufacture Complex Drive Systems, but Also Test and Optimize Them Under Realistic Conditions

The integration of the VL 6 complements Zoerkler's impressive machinery with manufacturing technologies such as turning, milling, grinding, gear cutting, gear grinding, bevel gear grinding, and eroding as well as testing facilities. The company has a high-performance test stand for helicopter gearboxes with a capacity of up to 2 x 4 megawatts as well as special test stands for e-mobility applications. This equipment underscores Zoerkler's ability not only to manufacture complex drive systems but also to test and optimize them under realistic conditions.

Zoerkler's expertise encompasses a wide range of gearing technologies, including the production of internal gears, ring gears, and bevel gears for helicopters. The company is particularly proud of its ability to create bevel gear ratios other than 90 degrees—a specialty highly valued in the aviation industry.

The successful integration of the VL 6 into Zoerkler's production processes underscores the company's commitment to continuous innovation and quality improvement. With this investment, Zoerkler consolidates its position as a technology leader in the manufacture of precision drives and prepares for future challenges in the rapidly evolving mobility industry.

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