Market leader in the machining of aluminum profiles for rail technology.
Travelling Column ENDURA® 1006LINEAR with 2 portals for the machining of large-volume aluminum profiles.
SIDE WALLS, ROOF AND FLOOR ASSEMBLIES
Travelling Column ENDURA® 1006LINEAR
- Work area division for 3-place machining
- Individual clamping concepts and fixtures on customer request
- up to 295 ft X-travel
- travelling operator cabin for better process monitoring
Customized clamping technology
for rail applications
Specialist for stringer and profil machining
Highly dynamic 5-axis machining of long workpieces with our long bed profile milling machine ENDURA® PRO LINEAR
- Encapsulated machining area
- Flexible workpiece clamping systems
- Rapid traverse 2,5"/min.
- Up to 2,5" X-travel
FOOKE FRICTION STIR WELDING - Strong joints for the industry
Shorter processing times and fully automatic process monitoring with FSW systems from FOOKE
FOOKE FRICTION STIR WELDING
Welding depths up to 4"
FOOKE TURNKEY-solutions for the rail industry
PROCESS CONSULTING AND DEVELOPMENT
Machining strategies | machining and measuring programs
TECHNOLOGY - MACHINE CONCEPT (MILLING, FRICTION STIR WELDING, WATER JET CUTTING)
Customized design according to requirements | Optimized machine design | Tool selection| Chips and dust extraction systems
MEASUREMENT
Detection of component deviations, component positions
CLAMPING TECHNOLOGY
Individual clamping concepts | Flexible clamping systems | Partial or full automation
DEMONSTRATION CENTER
Preliminary tests and evaluation | Tests | Preliminary tests
PROCESS INTEGRATION AND MONITORING
Process introduction and monitoring | Data documentation for quality assurance purposes
HALL MANAGEMENT
Foundation design | Air management | Sound insulation |
INDIVIDUAL CLAMPING SYSTEMS
Secure your process with the highest quality
FOOKE FRICTION STIR WELDING
High machine stiffness - low compliance - stable FSW process - high weld seam quality - high process reliability
FOOKE FRICTION STIR WELDING
5-axis simultaneous welding with maximum axial force of 60 KN
FLEXIBLE CLAMPING FIXTURE
Fully automatic positioning
FOOKE FRICTION STIR WELDING
Stable FSW process -> high weld seam quality
Force control / distance control / seam tracking / gap monitoring
Aluminum Extrusion Milling
High-Performance Aluminum Extrusion Milling for Complex Rail Profiles
In the global rail industry, the requirements for production technology are clear: They need to be big, fast, reliable, and, above all, robust. As modern high-speed trains and light rail vehicles are increasingly manufactured from large-volume aluminum profiles, the need for specialized machining centers has never been greater.
At FOOKE, we recognized this shift early on. As far back as the 1990s, we developed advanced aluminum extrusion milling systems and turnkey production centers in close cooperation with industry leaders. Today, we have consistently evolved our technology to meet ever-increasing demands for precision and throughput. This commitment to innovation has made us the global market leader in this segment.
Our expertise goes beyond milling. To provide a truly comprehensive solution for rail vehicle manufacturing, our portfolio includes:
- High-End Milling Centers: Engineered for maximum rigidity and high-speed performance.
- Friction Stir Welding (FSW): State-of-the-art systems for high-strength, low-distortion joining of aluminum.
- Turnkey Tooling: Custom welding and joining fixtures, as well as specialized assembly and erection stands.
Reliable. Modern. Economical. FOOKE is your strategic partner for the future of rail manufacturing.
Aluminum Extrusion Milling
High-performance milling for the rail industry: We deliver custom, high-precision solutions designed for maximum efficiency and superior manufacturing quality.
Precision Floor Assembly Machining
Case Study: How a Major Railway OEM Reduced Machining Time by 43%
For over 20 years, a leading Railway OEM in Germany has relied on FOOKE technology for high-precision aluminum profile machining. But how do you revolutionize a process that is already considered an industry standard?
By rethinking the entire production chain—from the machine's core architecture to the cutting edge—we implemented a next-generation gantry mill equipped with state-of-the-art drive technology and innovative milling strategies.
The Impact:
- 43% Reduction in total machining time.
- Dramatic ROI Improvement through increased throughput.
- Superior Surface Quality with modernized 5-axis tool paths.
Discover the key factors behind this success and learn how FOOKE can optimize your production efficiency.
Precision at Scale
Floor Assemblies, Side Walls, and Roofs
Mastering Large-Scale Aluminum Profile Machining with the FOOKE ENDURA®
The manufacturing of expansive floor assemblies, side walls, and roof sections requires more than just size—it demands extreme structural rigidity and uncompromising dimensional accuracy. The FOOKE ENDURA® 1006 LINEAR sets the global benchmark, enabling the seamless, continuous machining of components up to 90 meters (approx. 295 feet) in length.
Maximize Throughput with Advanced Process Control:
- Multi-Station Machining: Our intelligent workspace partitioning allows for simultaneous machining at multiple stations, drastically increasing machine utilization.
- Custom Workholding Solutions: Individualized clamping systems guarantee maximum process stability and part repeatability, even for the most complex geometries.
- On-Board Operator Cabin: The traveling operator cabin ensures 360° visibility and real-time process control, directly at the point of engagement.
Your Competitive Advantage: Manufacturers in the rolling stock industry benefit from fully reproducible quality, minimized setup times, and rock-solid production processes for large-volume aluminum profiles.
High-Dynamic Precision
Aluminum Profiles in Rail Vehicle Manufacturing
Mastering Long-Format Extrusions for Car Bodies and Roof Structures
The production of long-format aluminum profiles for modern rolling stock requires a machine that balances extreme structural stability with high-speed dynamics. The ENDURA® PRO LINEAR long-bed milling center was specifically engineered to meet these challenges, offering a fully enclosed workspace and flexible workholding solutions for maximum safety and precision.
With X-axis travel ranges up to 60 meters (approx. 197 feet), the ENDURA® PRO LINEAR enables the continuous, seamless machining of oversized profiles, eliminating the need for complex re-clamping and reducing the risk of tolerance stacking.
Technical Performance & Manufacturer Benefits:
- High-Velocity Machining: Achieve rapid traverse speeds of up to 65,000 mm/min (2,559 ipm) for minimized non-productive time.
- Superior Surface Integrity: Consistent, high-quality finishes across the entire length of critical car body profiles.
- Maximum Process Reliability: State-of-the-art linear drive technology ensures repeatable accuracy and long-term durability.
- Shortened Throughput Times: Optimized for high-volume manufacturing of roof segments, side walls, and floor beams.
Precision Face Milling for Safety-Critical Components
Bogie Attachment
Ensuring Structural Integrity and Seamless Assembly
Bogie attachments are the vital link between the car body and the chassis. Given their role in load-bearing and safety, these components demand the highest levels of precision and structural consistency. The ENDURA® 500 Overhead Gantry Milling Machine is specifically designed to machine these critical parts with maximum rigidity and zero vibration.
By achieving absolute surface flatness, the ENDURA® 500 eliminates assembly gaps and reduces the need for manual shimming, significantly streamlining the final integration of the bogie and car body.
Why FOOKE Leads in Bogie Interface Machining:
- Vibration-Free Stability: The overhead gantry design absorbs cutting forces, ensuring a superior surface finish even during heavy-duty face milling.
- Precision Flatness: Achieve the tight tolerances required for safety-critical interfaces, ensuring perfect alignment between the vehicle frame and the chassis.
- Streamlined Assembly: High-precision surfaces mean faster bolt-on processes and reduced downtime in the assembly line.
- Reliable Safety Standards: Machine safety-relevant components with documented, repeatable quality.
Precision for Every Profile
Custom Workholding & Clamping System
Engineered Stability for High-Volume Manufacturing
The success of machining large-scale aluminum profiles depends entirely on the stability of the setup. Standard solutions often fail when dealing with 90-meter components or complex geometries. At FOOKE, we develop flexible, custom workholding systems engineered specifically for your unique part requirements.
Our fully automated positioning systems and optimized support structures eliminate the guesswork, drastically reducing setup times and ensuring consistent, high-precision quality across every stage of the manufacturing process.
The FOOKE Advantage in Workholding:
- Fully Automated Setup: Intelligent clamping units that position themselves automatically based on the CAD data, minimizing human error.
- Vibration Dampening: Engineered support structures that absorb resonance, allowing for higher feed rates and superior surface finishes.
- Maximum Repeatability: Achieve the same high-tolerance results for the 1st part and the 1,000th part.
- Process Reliability: Secure clamping for 5-axis simultaneous machining, even during high-velocity material removal.
Streamline Your Milling Workflow with FOOKE Setup Stands
Precision Fixturing for Large-Scale Aluminum Extrusions
FOOKE setup stands are engineered to handle the complexities of heavy-duty aluminum profiles. By integrating high-precision alignment, mounting, and welding into a single workflow, our stands ensure your workpieces are mill-ready from the moment they are secured.
Why FOOKE Stands Make the Difference:
- Rock-Solid Stability: Eliminate vibration and deflection during high-speed milling.
- Precision Positioning: Drastically reduce setup times and ensure exact tolerances for large-scale structures.
- Optimized for Rail & Aerospace: Purpose-built for the rigorous demands of rolling stock and large-format manufacturing.
- Waste Reduction: Minimize scrap and costly rework by achieving "first-time-right" alignment.
Our Legacy of Excellence in Rail Infrastructure
Trusted by Global Leaders to Define the Future of Transportation
ALSTOM │ AMM MANUFACTURING │ BOMBARDIER │ HAI HAMMERER ALUMINIUM INDUSTRIES │ SIEMENS MOBILITY │ STADLER │ ST EXTRUDED PRODUCTS (STEP G) │ …
FOOKE Product range
Compact Gantry Milling Machine
ENDURA® 400LINEAR
- NEW - highly efficient for plastics processing
- Large machining area, small installation surface, can be set up without foundations
- Direct drive motors in all axes (linear and torque motors)
- High structural rigidity, highest dynamics and best accuracies
- Easy transport and short commissioning due to compact machine design
- Consistently high precision due to temperature stability of the machine structure
- Travels up to 106.3“ x 78.7“/118.1“ x 47.2“
- Range of materials: plastics, CFRP/GFRP, modeling block material, aluminum
Gantry Milling Machine
ENDURA® 600LINEAR
- Very spacious machining area
- Loading at ground level
- Optimal dust extraction and chip conveyor concepts
- Direct drives in all axes (linear and torque motors)
- Entry model for 1:1 processing in vehicle design
- Individual concepts for highest accuracies of large-scale components in aviation
- Excellent productivity in the machining of multi-purpose large workpieces
- Customized solutions for clamping technology and suction systems
- Individual axis length configuration
- Travels up to 196.9“-1,181.1“ x 110.2“/137.8“ x 59.1“/78.7“/90.6“
- Range of materials: plastic, CFRP/GFRP, model building block material, aluminum
Compact Gantry Milling Machine
ENDURA® 700LINEAR
- Our bestseller! Proven since 2004, continuously optimized
- Large machining area, small installation surface, can be set up without foundations
- Direct drive motors in all axes (linear and torque motors)
- High structural rigidity, highest dynamics and best accuracies
- Easy transport and short commissioning due to compact machine design
- Consistently high precision due to temperature stability of the machine structure
- 5-sided machining of all common automotive components
- Highly efficient productivity in the machining of aluminum components
- Modular design allows extension of X travel as XL version
- Thermal decoupling of short-term temperature fluctuations by Thermo Guard
- Travels up to 59.1“/86.6“/157.5“/216.5“ x 78.7“/110.2“/137.8“ x 59.1“
- Range of materials: plastics, CFRP/GFRP, modeling block material, aluminum, cast iron, steel
Compact Gantry Milling Machine
ENDURA® 7000LINEAR
- For high-performance heavy-duty machining of high-strength materials
- Large machining area, small footprint, foundationless installation
- Thermosymmetrical machine concept
- High structural rigidity, highest dynamics and outstanding accuracies
- Material range: steel, cast iron and aluminum
- Direct drives in all axes (linear and torque motors)
- Travels up to 118.1“/177.2“/236.2“ x 137.8“/177.2“ x 59.1“
- Range of materials: steel, cast iron and aluminum
Ganty Milling Machine
ENDURA® 900LINEAR
- Highly dynamic, for universal applications
- Direct drives in all axes (linear and torque motors)
- Excellent structural rigidity, highest dynamics and accuracies
- Very large enveloped machining area
- Market leader in 1:1 machining in German automotive design
- Perfectly matched machine concept for productive end-to-end machining from aluminum to steel
- Now also available in compact design
- Travels up to 196.9“ - 1,181.1“ x 118.1“/137.8“/157.5“/177.2“ x 59.1“/ 82.7“/ 98.4“/118.1“
- Range of materials: plastic, CFRP/GFRP, modeling block material, aluminum, cast iron, steel
Compact Gantry Milling Machine
ENDURA® 900LINEAR
- Large machining area, small installation surface, can be set up without foundation
- Direct drive motors in all axes (linear and torque motors)
- High structural rigidity, highest dynamics and accuracies
- Thermal decoupling of short-term temperature fluctuations by Thermo Guard
- Travels up to 98.4“/216.5“/350.4“ x 137.8“ x 59.1“
- Range of materials: steel, cast iron and aluminum
Longbed Profile Milling Machine
ENDURA® PRO LINEAR
- Specialist for stringer and profil machining
- Highly dynamic 5-axis machining of long workpieces
- Material removal rates up to 11.0 l/min
- Flexible workpiece clamping systems
- Ergonomic loading
- Two-station component machining for process-parallel loading
- Monobloc machine bed design, modularly expandable
- Encapsulated machining area by bullet-proof lamellas
- Travels up to 196.9“-2,362.2“ x 63“/94.5“/122“x 43.3“/59.1“
- Range of materials: aluminum, composites (CFRP/GFRP)
Travelling Column MIlling Machine
ENDURA® 1000LINEAR
- Specialist or large volume workpieces
- Ergonomic loading
- Travelling operator cabin for optimal process monitoring
- Traveling tool changer
- Market leader in the machining of aluminum profiles for the rail technology
- Individual clamping concepts and fixtures on customer request
- Available with mechanical drive components or modern linear motor drives
- Three-station component machining for process-parallel loading and unloading
- FSW retrofit solution for friction stir welding with max. axial force of 25 kN
- Travels up to 196.9“-2,362.2“ x 177.2“ x 63“/74.8“/82.7“
- Range of materials: plastic, CFRP/GFRP, aluminum, cast iron, steel
Plate Milling Machine
ENDURA® 800
- Face milling machine for large aluminum precision plates
- Highest accuracies due to extremely rigid machine structure
- Finish operation in one milling process
- Ergonomic loading
- Surface quality < 0.4 µm
- Milling tool up to Ø 122.0"
Driving Maximum ROI in Aluminum Machining
Elevating Your Rail Manufacturing Standards
Our US-based team is ready to discuss your milling, fixturing, and turnkey requirements.
Phone: (248) 218 5880
E-Mail: info[at]fooke-usa.com
