Aptiv develops and manufactures connectors, busbars, cable and RF assemblies, and software for automated and electrified systems.
Aptiv Services Deutschland GmbH
Wuppertal (DE) · Global presence in 23 countriesNew on Amplifa
About Aptiv
Aptiv is a global technology company that designs, develops, and manufactures connection and protection solutions for electrical systems in demanding environments. The Engineered Components portfolio includes high-voltage, low-voltage, and high-speed data connectors, hermetic interconnects, RF and microwave solutions (up to 110 GHz), stamped and extruded busbars, cable and wire assemblies, as well as electronics assemblies such as electrical centers, fuse boxes, and media modules. Manufacturing capabilities include overmolding, insulation layer extrusion, stamping, bending and twisting of busbars, laser ablation, laser welding, vacuum brazing, explosion welding, and diffusion bonding. Materials include, among others, copper (Cu-OF, Cu-ETP), aluminum, stainless steel, titanium, PA12, PPS, PTFE, and Ceramax ceramics. Customers come from automotive, commercial vehicles, aerospace & defense, telecommunications, medical technology, renewable energy, space, and industry. Aptiv is present with more than 51,000 employees across 76 production sites and 11 technical centers in 23 countries; the German entity Aptiv Services Deutschland GmbH is headquartered in Wuppertal.
- Site
- Wuppertal
- Processes
- Hermetic connectors / glass-to-metal and ceramic feedthroughs (Ceramax), Laser welding (hermetic housings, lids, feedthroughs), Vacuum brazing, Explosion welding (EXW), Diffusion bonding, Hermetic microwave packaging solutions, Overmolding (cable assemblies, overmolded busbars), Extruded busbars (manufacturing of busbars with extruded insulation layer)
- Materials
- Copper Cu-OF, Copper Cu-ETP, Aluminum, PA12 (Polyamide 12), PA12 HP (amorphous polyamide 12), PPS (Polyphenylene sulfide), Titanium, Stainless steel
- Certificates
- AS9100, AS7003, ISO 13485, IPC/WHMA-A-620 (Class 3), ISO 9001, OHSAS 18001, ISO 14001
- Employees
- 51.000+
- Industries
- Automotive, Commercial Vehicles, Aerospace & Defense, Telecommunications, Medical Technology, Renewable Energy
- 01
Engineering and Design
- 02
Material Selection
- 03
Stamping/Extrusion/Bending
- 04
Joining (Laser Welding, Vacuum Brazing, Diffusion Bonding)
- 05
Overmolding/Coating
- 06
Assembly and Harness Manufacturing
- 07
Testing and Validation
Materials and Processes
Copper Cu-OF
Highly conductive conductor material for stamped and extruded high-voltage busbars.
Copper Cu-ETP
Cu-ETP copper as an alternative for busbar conductors.
Aluminum
Conductor and housing material for busbars and hermetic interconnects.
Polyamide 12
Standard extrusion insulation for battery busbars up to 105°C long-term temperature.
Amorphous polyamide 12
High-temperature insulation up to 130°C with CTI 600 for short creepage distances.
Polyphenylene sulfide
Thermally and chemically stable insulation for charging busbars.
PTFE
Dielectric in semi-rigid coaxial cables.
Ceramax ceramic dielectric
Multiphase ceramic dielectric that replaces glass in hermetic feedthroughs.
Hermetic Joining
Laser welding, explosion welding, vacuum brazing, and diffusion bonding for stainless steel, aluminum, and titanium housings.
Overmolding
Overmolding of cable assemblies and busbars with thermoplastics.
Sites
Wuppertal
DEGerman headquarters
- Busbar bending machine (bending and twisting)
Components and Products
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Hermetic connectors / glass-to-metal and ceramic feedthroughs (Ceramax)Joining | – | – | – | – | Stainless steel, Aluminum, Titanium, Ceramax ceramic, Glass |
| Laser welding (hermetic housings, lids, feedthroughs)Joining | – | – | – | – | Stainless steel, Aluminum, Titanium |
| Vacuum brazingJoining | – | – | – | – | Stainless steel, Aluminum, Titanium |
| Explosion welding (EXW)Joining | – | – | – | – | Stainless steel, Aluminum, Titanium |
| Diffusion bondingJoining | – | – | – | – | Stainless steel, Aluminum, Titanium |
| Hermetic microwave packaging solutionsAssembly | – | – | – | – | Stainless steel, Aluminum, Titanium, PolyIron absorber, Hydrogen getter |
| Overmolding (cable assemblies, overmolded busbars)Plastics | – | – | – | – | Thermoplastics (among others PA12, PPS) |
| Extruded busbars (manufacturing of busbars with extruded insulation layer)Plastics | – | – | – | – | Copper (Cu-OF, Cu-ETP), Aluminum EN AW-1070A H112, PA12, PA12 HP, PPS |
| Stamping, bending, and twisting of busbars (punched, extruded busbars)Forming | – | – | – | – | Copper, Aluminum |
| Laser ablation/stripping of busbar contact areasSurface | – | – | – | – | PA12, PPS |
| Powder coating of busbarsSurface | – | – | – | – | Copper, Aluminum |
| Cable and wire assemblies / harness manufacturing (Assembly & Harness)Assembly | – | – | – | – | Copper, Fiberglass, PTFE |
| Coaxial cable manufacturing (vertically integrated semi-rigid coax cables, precise CNC bendAssembly | – | – | – | – | Copper, Tin-plated aluminum, Silver-plated copper-clad steel, PTFE |
| High-frequency and microwave connectors and assemblies (DC to 110 GHz)Assembly | – | – | – | – | Stainless steel, Aluminum, Titanium, Copper, Fiberglass |
| Electronic assemblies (electrical centers, fuse boxes, media modules, wireless charging)Assembly | – | – | – | – | – |
| Testing and validation services (test and validation laboratories)Testing | – | – | – | – | – |
| Engineering services (design, development, custom solutions)Engineering | – | – | – | – | – |
| High-voltage power supply solutions (400V–1000V, up to 250A)Assembly | – | – | – | – | Copper, Aluminum |
1 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Busbar bending machine (bending and twisting) | – | – | – | – | – |
Additional services
Reference customers
Quality
Aptiv complies with industry-specific management system and process standards such as AS9100, ISO 13485, and IPC/WHMA-A-620 Class 3; hermetic assemblies are manufactured in vertically integrated production with in-house machining, laser welding, vacuum brazing, and coating. Test and validation laboratories in Europe and North America with over 200 employees and 30 years of experience support product qualification.
| Evidence | Wuppertal |
|---|---|
| AS9100 | |
| AS7003 | |
| ISO 13485 | |
| IPC/WHMA-A-620 (Class 3) | |
| ISO 9001 | |
| ISO 14001 | |
| OHSAS 18001 |
History
- 1985
Research in the automotive sensor field, know-how from Hughes Aircraft Corp.
- 1994
Demonstration of integrated concepts for radar collision warning, occupant detection, and driver assistance
- 1999
Industry's first mass production of a radar-based adaptive cruise control
- 2001
Introduction of radar-based backup assist for the volume market
- 2007
Industry's first sensor fusion of radar and image processing
- 2009
Industry's first solid-state radar on the market
- 2015
Industry's first integration of radar and image processing as a single unit (full Euro NCAP AEB rating)
- 2017
Industry's first multi-domain controller in the Audi A8
- 2020
Global radar supplier with development centers in every region
- seit 2015
Contribution to avoiding around 480 million tonnes of CO2 emissions through the high-voltage portfolio
- 2020
Introduction of sustainability commitments
- 2025
Implementation of the sustainability strategy; planned spin-off of the Electrical Distribution Systems business segment as of April 1 into two independent companies