60 years of initiatives
Celebrating six decades in business means far more than simply marking a milestone. For Fill, these 60 years represent a legacy of continuous innovation and a commitment to helping shape the future. What began in 1966 as a modest metal workshop with an attached petrol station has developed into an internationally recognised specialist in high-tech plant engineering.
This remarkable development has been driven by a philosophy of always looking ahead rather than standing still. This forward-looking approach was clearly reflected at this year’s Fill Innovation Days, where the company demonstrated how modern technologies are continuously being developed and expanded. The focus extends beyond the development of new solutions to include promoting automation, accelerating digital transformation and creating innovative business models that prepare customers for the future.
Smart data as the foundation for next-generation manufacturing
Alongside an extensive partner exhibition, the Fill Innovation Days offered valuable insights into the company’s latest technological advances. One of the standout topics was the significant acceleration of robot programming, made possible by a smarter use of design data.
Instead of processing complete component geometries, today’s offline programming methods identify only the areas relevant to machining. Key features such as edges and splines are automatically extracted from this information, enabling robot paths to be generated much more efficiently.
The focus of this development is not on the robot itself, but on the quality and structure of the underlying data. Thanks to model-based definition (MBD), CAD models now contain machine-readable manufacturing information, including weld locations, tolerances and machining specifications. This embedded process data can be interpreted directly by the software and converted into automated robot commands without manual intervention.
When high-quality design data is available, programming tasks that used to take several days can now be completed within a few hours. The underlying principle is clear: Successful automation begins long before production starts – it begins with intelligent digital product data.
AI-supported quality control opens up new insights into foundry production
Artificial intelligence also played a central role at the Fill Innovation Days, particularly in the field of automated casting inspection. The presentations illustrated how AI is revolutionising quality assurance by overcoming many of the limitations of conventional image processing systems.
Unlike conventional solutions, AI-based inspection can reliably detect casting defects, even when components are in different positions or orientations. This shift places data at the heart of the process, making comprehensive, high-quality datasets one of the most valuable resources in modern manufacturing.
At the same time, the speakers emphasised that today’s industrial AI remains highly specialised. Its performance depends entirely on the quality and quantity of the available training data. To detect defects consistently, AI models typically require hundreds of representative examples for each defect category. Without this foundation, detection accuracy drops rapidly.
The greatest benefit, however, extends beyond automated defect detection. By analysing large volumes of inspection data over an extended period, AI uncovers recurring patterns and process correlations that would otherwise remain hidden. These insights enable manufacturers to identify the root causes of quality issues and implement targeted improvements, thereby transforming individual defects into valuable knowledge for the continuous optimisation of the casting process.
Advances in gravity casting through robotics and predictive process control
Another highlight of the Fill Innovation Days was the latest progress in gravity casting technology, where automation is helping to eliminate one of the industry’s greatest challenges: the variations associated with manual casting processes. Robot-assisted solutions such as the Robocast system are designed to ensure greater consistency, repeatability and overall process reliability.
Several technological innovations contribute to this improvement in performance. The molten metal is fed under an inert gas atmosphere to minimise oxidation, whilst a bottom-up casting process reduces turbulence during mould filling. Furthermore, precisely controlled flow rates ensure that each casting cycle follows the same parameters, resulting in stable and reproducible component quality.
The process is further optimised by advanced simulation tools that fine-tune the casting conditions even before production begins. Early applications of machine learning are also opening up new possibilities by predicting the expected quality of a component whilst it is still being manufactured. Rather than relying solely on post-production inspections, manufacturers can increasingly prevent defects through data-driven process control, thereby moving from reactive quality control to proactive quality assurance.
Investing in talent as the foundation for future innovation
Whilst advanced technologies underpin much of Fill’s business, the company emphasises that sustainable innovation depends on the people behind it. Alongside its investments in automation and digitalisation, Fill places great importance on nurturing future talent and creating opportunities for the next generation.
This commitment is reflected in extensive training programmes, specialised training workshops and a consistently high standard of in-company vocational training. Through initiatives such as the ‘Future Lab’, school pupils gain early insights into modern manufacturing technologies, enabling them to explore technical careers long before they enter the world of work.
Fill also welcomes thousands of visitors every year, including school groups, customers and industry partners, offering them first-hand insights into advanced production technologies and technical innovations. By fostering curiosity and hands-on learning at an early stage, the company aims to build a sustainable pool of skilled workers. The underlying philosophy is clear: securing the workforce of tomorrow begins with inspiring young people today.
Creating a working environment that promotes both career progression and wellbeing
Fills’ vision for the future goes beyond technological innovations and also encompasses the way in which people experience their working environment. Rather than viewing the workplace merely as a production facility, the company has designed its expanding campus to promote both professional success and quality of life in everyday life.
Staff benefit from a wide range of services that make it easier to balance work and private life. These include on-site childcare, fitness and wellness facilities, physiotherapy services and even a hairdressing salon – all located directly on the company premises. Furthermore, dedicated event and communal spaces foster collaboration, social interaction and closer ties between staff and the surrounding region.
Sustainability is another key component of this approach. Investments in solar energy and a more self-sufficient energy infrastructure reflect the company’s long-term commitment to environmentally conscious operations, whilst also creating a modern and resilient workplace.
Together, these initiatives highlight Fill’s ambition to offer more than just a place to work. By combining an innovative working environment with comprehensive staff support and sustainable infrastructure, the company continues to pursue its long-standing goal of creating exceptional workplaces.
Conclusion: Shaping the future through connected thinking
Six decades of growth have shown that sustainable innovation is rarely the result of a single breakthrough. At Fill, progress is achieved through a holistic approach that combines advanced technologies, digital processes and human expertise. High-quality design data forms the basis for automated manufacturing, artificial intelligence supports smarter decision-making, and simulation technologies optimise production long before the first component is manufactured.
Equally important are the company’s ongoing investments in its workforce. Engineers, skilled workers, apprentices and technology specialists remain at the heart of every innovation and ensure that the digital transformation is guided by experience, creativity and practical knowledge.
This holistic perspective shapes Fill’s vision for the future. Rather than simply developing machines, the company creates intelligent production systems in which technology, data and people work together seamlessly. It is this combination of long-term vision, continuous innovation and investment in human potential that has characterised Fill’s success over the last 60 years and continues to drive its future.