Tool-based production is recommended for 5,000-10,000 units per year. This enables very high speeds at high volumes. For example, a 12-step deep-drawing process (see image) can achieve a very high production speed (1 second per unit). Depending on the product specifications, tool-based production can be combined with 3D laser cutting, CNC milling, or other manufacturing technologies.

Combined laser cutting and punching (3000 x 1500 mm)

2D laser cutting (3000 x 1500 mm)

3D laser cutting (4000 x 1500 x 750 mm)

Axial hydraulic guillotine shears
 
Punching (40-200 t)

Punching from coil (up to 160 t)

Straightening (max. width 220 mm)

Robot bending cells (up to max. 3100 mm)
Bending Cell Xpert 150 Pro
Mobile Bending Cell Xpert 80
Mobile Bending Cells Xpert 40
Bending machines (up to max. 4100 mm)
TruBend 5230
TruBend 5130
Xpert 150
TruBend 5085
TruBend 7036

In contrast to 2D laser cutting, cubic parts can be cut to fit perfectly with 3D laser cutting. The laser processing of three-dimensional components enables new design possibilities. This allows material-saving construction, and weight optimizations can be realized.

Axis travel range X‑axis 4000 mm Axis travel range Y‑axis 1500 / 2000 mm Axis travel range Z‑axis 750 / 1000 mm Axis travel range B‑axis ± 135 ° Axis travel range C‑axis n x 360 ° Axis travel range Dynamic cutting optic ± 9 mm

Metal spinning is a very old craft. Particularly in the production of parts with rotational symmetry - small and medium quantities - metal spinning is superior to other methods. In metal spinning, a sheet metal disc is pressed centrically - with the pre-spinner - against the spinning mold and set in rotary motion. The spinning roll forms the rotating disc stage by stage until the material lies against the spinning mold. The forming process is controlled by two axes. With perfect control of the process, the wall thickness of the material remains constant. In addition to the forming of discs, preformed components such as deep-drawn ones can also be further reduced in diameter by pressing. 

Deep drawing is the tensile compression forming of a sheet metal blank into a hollow body open on one side, or of a pre-drawn hollow body into one with a smaller cross-section, without deliberately changing the sheet thickness. Deep drawing can be used in many different areas. One reason for this is that many metals can be formed using this process, starting with aluminium, brass, copper, sheet steel, stainless and acid resistant alloys, but also heat resistant and various other metal alloys. Deep-drawn parts can be found in the automotive, engineering, aerospace, solar, domestic, energy, chemical and many other industries.

Hydromechanical deep drawing with our Dieffenbacher enables higher drawing ratios to be achieved than with conventional drawing processes.

Complex geometries, flared tubes, forming intersections, parts with high surface quality, parts from multi-layer sheet metal, prototype production, small and medium series production.

As one of the leading suppliers of hydroforming in Europe and Switzerland, our partner company Egro Industrial Systems AG has a 900-tonne press with 1,000 bar Hydromec pressure. With this press, the range of services can be covered up to a size of 1,400 mm x 1,600 mm.

Fully automatic, semi-automatic, or with manual insertion: Entièrement automatique, semi-automatique ou avec insertion manuelle : le nombre de pièces au cours de la durée de vie détermine la technologie de l'outil et donc les coûts initiaux de l'outil.

Hybrid manufacturing defines a production process that combines traditional sheet metal processing (e.g., 3D laser cutting or tool-based deep drawing) with tool-free processing. For example, in the case of train seat shells (see photo), the mold is first created using a tool-based deep drawing process, followed by precise machining of the edges using CNC milling technology. The combination of the various technologies and manufacturing methods enables customer-specific pricing.