ECM
Shaping the
future.
Delivering excellence.
Electro Chemical
Machining (ECM)
Electro chemical machining (ECM) is an advanced machining technology that ensures maximum precision and minimal material wear. As an established full-service supplier and service provider in the manufacturing sector, Köppern has been offering customized ECM solutions since the 1960s – from raw material processing to finished components.
- Gentle processing—no structural changes due to electrolytic material removal and no additional heat input—absolute crack-free results are guaranteed.
- High-speed machining of complex geometric shapes—through parallel machining processes and significantly higher feed rates compared to erosion processes.
- Burr-free production—flushing with electrolyte solution creates flow-friendly, burr-free surfaces
- Hardness, toughness, and machinability are irrelevant—ECM is particularly suitable for machining high-strength materials regardless of mechanical properties.
process
Game changer in metal processing:
ECM delivers perfection
ECM Technology
Electro Chemical Machining (ECM) enables high-precision machining of metallic materials through electrolytic dissolution - completely contact-free and without thermal stress.
How does ECM work?
The workpiece (anode) and the tool electrode (cathode) are connected to a direct current source. A special electrolyte solution closes the circuit, removes metal ions and prevents mechanical wear. The exact workpiece contour is created by advancing the tool electrode - ideal for complex geometries.
Your advantages
Free-form surfaces and complex geometries
Even complex shapes such as curved and elliptical holes can be produced with maximum precision, without tool wear or material stress. This enables the manufacture of components with maximum design freedom, ideal for aerospace, medical technology, and industry.
No material wear
Perfect surface quality
The ECM process enables perfect surface quality with roughness values below Ra 0.4 µm, without any post-processing. Since the process is burr-free, there is no need for time-consuming finishing processes such as grinding or polishing.
Machining of difficult-to-machine materials
The ECM process enables the precise machining of extremely hard or difficult-to-machine materials such as titanium and nickel alloys without tool wear or material stresses. In contrast to conventional machining processes, even difficult-to-machine materials can be shaped efficiently.
Reduced processing times through parallel processing
The ECM process enables shorter processing times through the use of multiple tools that produce different geometries simultaneously. This allows high quantities to be manufactured with consistent repeat accuracy.
quality
Expertise Without Compromise
Unique expertise
For us, top quality means more than just meeting standards - we create real added value for our customers. Our aim is not only to meet your expectations, but to exceed them. We build long-term trust through precise manufacturing, reliable processes and close cooperation.
- Customized solutions – Tailored to your requirements
- Reliable partnership – Proven quality for leading companies
measuring machines
Cutting-edge technology
Quality assurance
Köppern-ECM has invested in advanced measurement technologies to precisely measure the complex geometries of the ECM process.Our goal: measurable quality for the highest demands.
- Thanks to specially developed CMM (Coordinate Measuring Machines) programs, we enable flexible adjustment, rapid adaptation, and the creation of precise measurement reports, contour drawings, and graphics—ideal for individual customer requirements.
- Our measurement services cover a wide range: from small to large components, using tactile and optical 3D coordinate measuring systems for maximum precision.
facilities
Precision. Efficiency. Sustainability.
Your advantages
Innovation durable
Köppern has been continuously developing electrochemical metalworking since 1965 and now offers high-precision, cost-effective solutions for contract manufacturing. Our wide range of services extends from the smallest workpieces to components weighing 15 tons and measuring 2.5 meters in diameter.
Stress-free manufacturing
Enhanced production
In addition to ECM technology, we offer the option of machining components weighing up to 50 tons. This means our customers benefit from a comprehensive manufacturing solution from a single source.
Manufacturing cutting-edge ECM
Whether individual parts or large series, classic ECM machining or PECM (precise ECM) – Köppern offers tailor-made solutions for your manufacturing requirements.
Innovation Meets Experience
Decades of expertise
– dedicated to your success
With decades of experience, Köppern offers customized solutions for process optimization—from analyzing technical challenges to implementing efficient manufacturing concepts. Our engineers and consultants support you in development, prototyping, and series production.
We manufacture ECM tools in-house and produce components ranging from single items to large series—always in accordance with high quality standards and individual customer specifications.
Aerospace certification
s according to EN 9100
Our many years of experience in the aviation industry were confirmed in 2022 by successful certification according to EN 9100. This standard exceeds the requirements of ISO 9001 and underlines our competence as a reliable partner in the aerospace sector.
Next step: NADCAP accreditation to meet the highest quality standards.
pharmaceutical
Innovative Solutions
for Tablets & Medical Components
Manufacture of tablet rollers
In the pharmaceutical industry, the demands on quality and reproducibility are increasing—similar to those in aerospace technology. ECM surpasses conventional machining techniques such as turning or milling and enables high-precision manufacturing.
One example is the manufacture of rollers for tablet production, which requires a constant tablet volume per mold. Thanks to the high repeatability of the ECM process, a low tolerance of ± 50 μm and an excellent surface quality of Ra = 0.4 μm can be achieved.
In addition, ECM offers maximum design flexibility: simply replacing the electrode is enough to change tablet shapes, add break lines, or emboss logos and dosage information.
Medical Components
ECM enables the production of complex geometries that would not be possible using conventional methods. One example is the manufacture of a stainless steel prosthesis with a helical spiral, created by a rotating copper electrode that was simultaneously guided forward during the ECM process.
History
Shaping the Future
A pioneer in
ECM technology
The collaboration with Rolls-Royce on ECM machining of engine parts began back in 1966.
In the 1970s, Köppern established itself as a leading ECM contract manufacturer and worked with renowned companies such as MTU, Siemens, and Tuthill Powerplant Technologies.
A further technological leap was made in 2007 with the investment in PECM (Combined Pulse ECM), which combines precision and efficiency. In 2015, Köppern built one of the largest ECM systems in Europe with state-of-the-art pump, rotary table and CNC technology.
1965
Köppern's first ECM system
1992
Building ECM capacities in Venezuela
1995
Development and construction of an ECM system for Rolls Royce engine parts
1996
Building ECM capabilities in Australia
2007
Development of a pulse ECM system
2012
Building ECM capacities in India
2015
Construction and commissioning of one of the world's largest ECM plants
2022
Setup and commissioning of an ECM machining center for series production of turbine discs
2022
Certification of the ECM division according to EN 9100
State-of-the-art ECM
manufacturing worldwide
Today, Köppern operates seven ECM machines in Hattingen with capacities ranging from 100 to 20,000 amps. Two additional machines are in use at plants in Venezuela and India. With over half a century of experience and continuous innovation, Köppern sets standards in ECM technology, precision manufacturing, and industrial process optimization.
aerospace
Optimized Turbine Performance
Precision redefined -
for the aerospace industry
In aviation, every detail counts—especially when it comes to highly stressed engine components. Using ECM, we manufacture curved elliptical cooling holes in high-pressure turbine (HPT) discs for Rolls-Royce Germany.
- Crack-free, precise cooling holes for maximum safety
- Flow-optimized inlet and outlet contours for maximum efficiency
- Processing of high-strength materials where other processes fail
With ECM, we guarantee dimensional accuracy of ± 50 μm – absolutely burr-free and with perfect surface quality.
Complex housing parts
– precision at any scale
- 1.2 m conical ring with 12 high-precision rectangular openings
- Flügelförmige Taschen mit minimaler Wandstärke (<1,5 mm)
- Manufactured without rinsing slots for a flawless surface
industry
Precision Engineering
s with ECM Solutions
Precision Engineering
s with ECM Solutions
Where conventional manufacturing processes reach their limits, electrochemical metalworking (ECM) offers a precise and material-friendly solution. Particularly in safety-critical areas, it enables complex components with maximum reproducibility—without any mechanical stress.
Learn how we use ECM technology to implement demanding industrial applications.
High-efficiency briquetting
rings for hot briquetting processes
A classic example of an application from our roller press production is the insertion of large-format molds into briquetting rings with a diameter of up to 1,500 mm. Using multiple tools, four molds are pressed simultaneously into a hardened ring weighing up to 14 tons—an ECM application that is unique in terms of the weight of material removed, which exceeds 130 kg. The actual sinking time for four molds is only 8 minutes, which also pushes milling to its limits as a conventional manufacturing method for this material.
Ultra-precise filter components
for
demanding applications
Sometimes, even simple structures pose challenges for production planning, for example when conventional manufacturing methods are not permitted or appear uneconomical. In the image above, the PECM process is used to produce a grid structure of 2-3 mm wide square holes in a steel sheet. These sheet metal parts serve as filter elements in highly critical areas of nuclear power plants and are subjected to immense pressure and temperature loads. Due to the high requirements for the filter to be completely free of cracks, the only process that can be considered is one that "gently" removes the geometry without mechanical stress on the component – i.e., ECM, whereby economical machining for our customers is only possible through the use of up to 1,000 individual electrodes in a single tool.
Blade profiles for
stationary steam turbines
Our ECM technology has been used since the 1970s to manufacture complex turbine blades. The blades are produced from a closed, turned ring with maximum reproducibility.
Contact us
Contact us for your customized solution
Would you like to find out more about our ECM solutions? Our experts will be happy to advise you and work with you to develop a solution that is precisely tailored to your production requirements.
