Manufacturer of welded wire frames, staple wires and bent parts for the automotive industry.
A.I.T. Metallbearbeitung GmbH & Co. KG
Alpirsbach (DE) · Chomutov (CZ) · Atlanta (US)New on Amplifa
About A.I.T. Metallbearbeitung
Since 1990, A.I.T. Metallbearbeitung GmbH & Co. KG has been developing and manufacturing welded wire frames, staple wires and wire bent parts, primarily for vehicle seats and vehicle interiors. The group comprises A.I.T. Innovationstechnik, A.I.T. Metallbearbeitung and A.I.T. wire forming Czech Republic. The range extends from one-off production to large-scale series of several million parts. In addition to CNC wire bending, 3D welded constructions made of wire, sheet metal and tube parts are manufactured fully automatically on robotic welding systems; metal and plastic parts are also processed into assembled modules. The high level of in-house production depth includes engineering with CAD (CATIA V5), prototype construction within two to three weeks, and in-house toolmaking for welding fixtures and gauges. Materials processed include bare iron wire, galvanized and phosphated spring steel wire, and copper-plated iron wire with wire diameters from 1.5 to 10 mm. Customers include, among others, Fehrer, proseat and renowned automotive manufacturers. Headquarters and competence center are located in Alpirsbach-Reutin in the Black Forest; another production plant is located in Chomutov (Czech Republic), and there is also a plant in Atlanta (USA).
- Site
- Alpirsbach
- Processes
- Wire bending (CNC wire bending machines, wire frames and bent parts), 3D welded constructions made of wire, sheet metal and tube parts (robotic welding), Assembly of assembled modules, Fixture making (welding fixtures, gauges, prototype welding fixtures), Prototype construction / prototype development (CAD CATIA V5, sample parts in 2-3 weeks), Quality assurance with laser measuring systems and tensile strength testing machines, Design/engineering (CAD CATIA V5, prototypes in 2–3 weeks), Toolmaking (welding fixtures, gauges, auxiliary and inspection equipment)
- Materials
- bare iron wire, galvanized spring steel wire, phosphated spring steel wire, copper-plated iron wire, Plastic, Bare iron wire, Galvanized spring steel wire, Phosphated spring steel wire
- Certificates
- DIN EN ISO 9001:2015, DIN EN ISO 9001:2015 (sales, A.I.T. Alpirsbacher Innovationstechnik GmbH &, DIN EN ISO 9001:2015 (Chomutov site, CZ), ISO 9001
- Founded
- 1990
- Employees
- approx. 180 (90
- Industries
- Automotive industry (vehicle seat/interior supplier)
- 01
Engineering / design (CAD CATIA V5, prototypes in 2–3 weeks)
- 02
Toolmaking (welding fixtures, gauges, prototype welding fixtures)
- 03
CNC wire bending (Wafios, one-off production to large-scale series)
- 04
Robotic welding (Panasonic, 3D welded constructions)
- 05
Assembly of modules (metal/plastic)
- 06
Quality inspection (laser measuring systems, tensile strength tests)
Materials & Processes
Bare iron wire
Processed into bent parts and wire frames with wire diameters from 2 to 10 mm.
Galvanized spring steel wire
For corrosion-protected wire bent parts in diameters from 1.8 to 3 mm.
Phosphated spring steel wire
For bend-resistant wire parts and frames in diameters from 1.8 to 7 mm.
Copper-plated iron wire
For special applications in wire diameters from 2 to 7 mm.
Plastic
Processing of plastic parts as part of assembled modules.
CNC wire bending
On around 60 CNC-controlled Wafios machines (single-head, double-head, four-head) with wire diameters from 1.8 to 10 mm.
Robotic welding
40 fully automatic Panasonic welding systems for 3D welded constructions made of wire, sheet metal and tube.
Tool and fixture making
In-house toolmaking for welding fixtures, gauges and prototype welding fixtures in Alpirsbach.
Sites
Alpirsbach-Reutin (Headquarters)
DEHeadquarters, competence/development center, production, toolmaking
- Part weight / size
- Wire diameters 1.5–10 mm
- Lot size
- One-off production to large-scale series (several million parts)
- Materials
- Bare iron wire, galvanized/phosphated spring steel wire, copper-plated iron wire, plastic
- 40 CNC-controlled Wafios wire bending machines (single-head, double-head, four-head)
- 20 fully automatic robotic welding systems (Panasonic)
- Special wire bending machine for staple wires 1.5–2 mm (developed with Wafios)
- Laser measuring system
- Tensile strength testing machine
- 12,000 m² of production space
Chomutov (Production plant CZ)
CZProduction plant (A.I.T. Wire Forming & Metal Technology CZ spol. s.r.o., Ctiborova 1192/1)
- Part weight / size
- Wire diameters 1.8–10 mm
- Lot size
- Series production for vehicle seat and interior components
- Materials
- Bare iron wire, galvanized/phosphated spring steel wire, copper-plated iron wire
- 20 CNC-controlled Wafios wire bending machines
- 20 fully automatic robotic welding systems (Panasonic)
- approx. 6,000 m² of production space
Atlanta (US plant)
USProduction plant (founded 2000)
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Wire bending (CNC wire bending machines, wire frames and bent parts)Forming | – | – | – | One-off production – Large-scale series of several million | bare iron wire, galvanized spring steel wire, phosphated spring steel wire, copper-plated iron wire |
| 3D welded constructions made of wire, sheet metal and tube parts (robotic welding)Joining | – | – | – | – | wire, sheet metal, tube |
| Assembly of assembled modulesAssembly | – | – | – | – | metal, plastic |
| Fixture making (welding fixtures, gauges, prototype welding fixtures)Engineering | – | – | – | – | – |
| Prototype construction / prototype development (CAD CATIA V5, sample parts in 2-3 weeks)Engineering | – | – | – | – | wire |
| Quality assurance with laser measuring systems and tensile strength testing machinesTesting | – | – | – | – | – |
8 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| CNC single-head wire bending machine | Wafios | – | – | – | Alpirsbach / Chomutov |
| CNC double-head wire bending machine | Wafios | – | – | – | Alpirsbach / Chomutov |
| CNC four-head wire bending machine | Wafios | – | – | – | Alpirsbach / Chomutov |
| CNC-controlled wire bending machines | Wafios | 60 | Wire diameters 1.8 - 10 mm | – | Alpirsbach (40) / Chomutov (20) |
| Special wire bending machine for staple wires 1.5 - 2 mm | Wafios | – | Wire diameter 1.5 - 2 mm | – | – |
| fully automatic robotic welding systems (welding power source, controller and robot) | Panasonic | 40 | – | – | Alpirsbach (20) / Chomutov (20) |
| Laser measuring system | – | – | – | – | – |
| Tensile strength testing machine | – | – | – | – | – |
Additional services
Reference customers
Quality
Quality assurance is carried out using laser measuring systems and tensile strength testing machines; the quality management system is certified to DIN EN ISO 9001:2015 by TÜV SÜD (main certificate for manufacturing and sales, including the Chomutov site).
| Evidence | Alpirsbach | Chomutov |
|---|---|---|
| ISO 9001 |
History
- 1990
Foundation of A.I.T. Metallbearbeitung GmbH & Co. KG by E. Franke and K.-H. Pfau in Alpirsbach (in Rötenbächle, former Dugena site).
- 1991
Relocation to the center of Alpirsbach (former Beutler site).
- 1993
Relocation to the former Steurer company premises.
- 1997
Purchase of land and planning of the Alpirsbach-Reutin plant.
- 1998
Construction phase at the Reutin site.
- 1999
Move to today's headquarters in Alpirsbach-Reutin; founding of Innovationstechnik.
- 2000
Founding of the US plant (Atlanta).
- 2003
Start of the Czech production site.
- 2006
Founding of the Czech plant (Veiprty).
- 2009
Relocation of the Czech plant to Chomutov (approx. 6,000 m²).
- 2010
Partner E. Franke withdraws.
- 2017
Planning of the extension to the production hall in Alpirsbach-Reutin.