System supplier for cable assembly, custom connectors and inductive components for automotive and industrial applications.
ALACsystems GmbH
KirchhundemNew on Amplifa
System Supplier for Connection Technology and Magnetics
ALACsystems GmbH has been based in Kirchhundem in the Sauerland region since 1993 and has evolved from a specialist for telecommunications accessories into a system supplier for automotive and industrial applications. The portfolio includes custom cable assembly (automatic and manual), connector solutions including BIZON® press-fit technology according to DIN EN IEC 60352-5, overmolded housings and hybrid components, electronic assemblies as well as transformers and inductive components for power supplies, e-mobility and renewable energies. Manufacturing includes high-pressure stamping processes (sheet thicknesses 0.2–2 mm), automated injection molding with insert and overmolding, vacuum potting, laser welding, winding, PCB assembly, wire and die-sinking EDM as well as in-house tool design and manufacturing. Materials processed include copper, high-performance plastics, ceramic ferrites, grain-oriented electrical steel, amorphous and nanocrystalline alloys, and aluminum (including die-cast aluminum heat sinks). Customers are Tier1 and Tier2 suppliers to the automotive industry, infrastructure operators, and manufacturers of charging stations, wallboxes and on-board chargers; assemblies for DC charging modules in the power range 50–350 kW are also part of the service spectrum. Series production is carried out according to IATF 16949 with weekly air and sea freight deliveries to the European market.
- Site
- Kirchhundem
- Processes
- Cable assembly / cable harnesses (automatic and manual), In-house cable assembly (automatic and manual), Custom connectors (new development, modification, adaptation), BIZON® press-fit technology (solder-free press-fit technology according to DIN EN IEC 60352-5), Injection molding (automated injection molding technology, insert and overmolding), Overmolding technology (overmolded housings / hybrid components, plastic-encapsulated leadframe, Laser welding (laser-welded housing covers), PCB assembly / electronic assembly manufacturing
- Materials
- Copper (wires, contacts, busbars, copper sleeves), Ceramic ferrites (MnZn, NiZn), Grain-oriented electrical steel based on silicon-iron (SiFe), Amorphous iron-based alloys, Nanocrystalline iron-based alloys, High-performance plastics, Aluminum (die casting, heat sinks), Copper
- Certificates
- ISO 9001:2015, IATF 16949:2016, ISO 14001:2015, AEO (AEO-DE AEOF 118110), ISO 9001, ISO 14001, IATF 16949, AEO
- Founded
- 1993
- Industries
- Automotive (Tier1/Tier2), E-mobility, Renewable energies (charging stations, wallboxes, on-board chargers), Industry, Telecommunications (historical)
- 01
Development and concept creation (Design for Manufacturing)
- 02
Prototyping and sample building, pre-series production
- 03
Tool design and manufacturing
- 04
Stamping technology, injection molding, winding, cable assembly
- 05
Assembly manufacturing and assembly (incl. potting, laser welding)
- 06
Testing laboratory and quality assurance
- 07
Logistics, warehousing and customs
Materials and Processes
Copper
Wires, contacts, busbars and copper sleeves for press-fit technology and wound components.
Ceramic Ferrites
Soft-magnetic core types for inductors and transformers.
Grain-oriented electrical steel (silicon-iron)
Core material for high-performance magnetic components.
Amorphous iron-based alloys
Soft-magnetic core material for high-efficiency inductors.
Nanocrystalline iron-based alloys
Soft-magnetic core material for demanding magnetics applications.
High-performance plastics
For injection-molded housings, overmolding (insert/overmolding) and potting.
Aluminum
Die-cast aluminum heat sinks with effective thermal management.
Locations
Kirchhundem
DEHeadquarters with development, manufacturing and testing laboratory
- Lot size
- Prototypes, pre-series, series
- Materials
- Copper, high-performance plastics, ferrites, electrical steel, aluminum
- High-pressure stamping processes
- Automated injection molding technology
- Insert and overmolding
- Vacuum potting
- Laser welding
- Wire and die-sinking EDM
- PCB assembly
- Automatic and manual cable assembly
- Automatic and manual winding
- In-house tool design and manufacturing
- High-performance assembly systems
- Environmental and testing laboratory
Products and Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Cable assembly / cable harnesses (automatic and manual)Joining | – | – | – | – | – |
| In-house cable assembly (automatic and manual)Joining | – | – | – | – | – |
| Custom connectors (new development, modification, adaptation)Engineering | – | – | – | – | – |
| BIZON® press-fit technology (solder-free press-fit technology according to DIN EN IEC 60352-5)Joining | – | – | – | – | Copper |
| Injection molding (automated injection molding technology, insert and overmolding)Plastics | – | – | – | – | High-performance plastics |
| Overmolding technology (overmolded housings / hybrid components, plastic-encapsulated leadframePlastics | – | – | – | – | High-performance plastics |
| Laser welding (laser-welded housing covers)Joining | – | – | – | – | Plastics |
| PCB assembly / electronic assembly manufacturingAssembly | – | – | – | – | – |
| Automatic and manual winding (wound components, transformers, inductors)Joining | – | – | – | – | Copper (wires), Ceramic ferrites (MnZn, NiZn), Grain-oriented electrical steel SiFe, Amorphous iron-based alloys, Nanocrystalline iron-based alloys |
| Automated vacuum potting (potting)Plastics | – | – | – | – | – |
| High-pressure stamping processes (stamped contacts, sheet thicknesses 0.2–2 mm)Forming | – | – | – | – | Copper, Metal strips |
| Wire and die-sinking EDMMachining | – | – | – | – | Metal |
| In-house tool design and manufacturingEngineering | – | – | – | – | – |
| Development and manufacture of high-performance assembly systems for connector systemsEngineering | – | – | – | – | – |
| Development & manufacturing of heat sinks (e.g. aluminum die casting)Casting | – | – | – | – | Aluminum |
| Automated and manual assemblyAssembly | – | – | – | – | – |
| Testing laboratory (insertion/extraction force, contact resistance, thermal shock, climate cycling,Testing | – | – | – | – | – |
| Magnetics: common-mode chokes (CMC), resonant converters (LLC), power filter modules (PFC),Engineering | – | – | – | – | Ceramic ferrites (MnZn, NiZn), Grain-oriented electrical steel SiFe, Amorphous iron-based alloys, Nanocrystalline iron-based alloys, Copper |
| Assembly manufacturing for DC charging modules in the power range 50–350 kWAssembly | – | – | – | – | – |
Additional services
Quality Management
The quality management system is aligned with national and international standards as well as the most demanding requirements of the automotive industry (APQP incl. DFMEA, PFMEA, SPC, MSA, PPAP) with 100% automatic process monitoring, 100% end-of-line testing and traceability of all components. The company's own environmental and testing laboratory tests, among other things, insertion/extraction force, contact resistance, thermal shock, climate cycling and whisker formation according to DIN EN 60352-5.
| Evidence | Kirchhundem |
|---|---|
| ISO 9001 | |
| ISO 14001 | |
| IATF 16949 | |
| AEO |
History
- 1993
Founded as a specialist for telecommunications accessories; development into a system supplier for automotive and industrial applications
- 2025
Participation in PCIM Expo 2025 in Nuremberg (Hall 6)