Stamping, forming and machined parts, assemblies, roll-formed products as well as toolmaking from metal for the supply industry.
Bernecker Umformtechnik GmbH
Mühlacker · Pausa · Krušovce (SK)New on Amplifa
About Bernecker
Founded in 1962, the Bernecker Group is a family-owned company with sites in Mühlacker (Bernecker Umformtechnik GmbH and Bernecker Engineering GmbH), Pausa (Bernecker rollforming & tubes GmbH) and Krušovce in Slovakia (BeShapeTech k.s.). The core business is the forming and joining of metals: stamped, deep-drawn and bent parts with sheet thicknesses from 0.1 to 6 mm, roll-formed parts and tubes, turned parts up to Ø 65 mm as well as custom milled parts with tolerances below 0.01 mm. In addition, assemblies and modules are assembled, prototypes and pre-series parts are manufactured, and the in-house toolmaking department produces progressive dies, transfer dies, drawing dies and prototype tools, jigs and fixtures, and roll sets. Materials include light metals, steels, stainless steels, surface-coated and high-strength materials, non-ferrous metals and specialty materials. Customer industries include automotive, aerospace, hydraulics, industrial and plant engineering, medical and laboratory technology, the electrical industry as well as electromobility and CO₂-based HVAC systems.
- Site
- Mühlacker
- Processes
- Stamped and formed parts (stamped, deep-drawn, bent, thermoformed), Stamped, deep-drawn and bent parts with sheet thicknesses 0.1 mm - 6 mm, Rollforming – custom roll-formed parts and tubes, Turned parts up to Ø 65 mm, Custom milled parts with tolerances below 0.01 mm, Servo press forming with transfer system, 8,000 kN press force, Assembly of subassemblies and modules, Hard turning (turning centres)
- Materials
- Light metals, Steels, Stainless steels, Surface-coated materials, High-strength materials, Non-ferrous metals, Specialty materials, Carbide
- Certificates
- IATF 16949:2016, ISO 9001:2015, ISO 14001:2015, IATF 16949, ISO 9001, ISO 14001
- Founded
- 1962
- Industries
- Automotive, Aerospace, Hydraulics, Industrial and plant engineering, Medical and laboratory technology, Electrical industry
- 01
Project consulting & profitability analysis
- 02
Material selection
- 03
Forming simulation & feasibility studies
- 04
Toolmaking (design, manufacturing)
- 05
Prototypes & pre-series parts
- 06
Stamping/forming technology, servo presses, laser cutting
- 07
Machining (turning, milling)
- 08
Rollforming & tubes
- 09
Assembly & module assembly
- 10
3D metrology & 100% camera inspection
- 11
Logistics & customer service
Materials & Processes
Steels
Various steels, including high-strength materials, for stamped, deep-drawn and formed parts.
Stainless steels
Stainless steels, among other things for the production of roll-formed products and stainless steel tubes in Pausa.
Light metals (aluminium)
Light metals for demanding stamped and formed parts.
Non-ferrous metals
Non-ferrous metals as a material for custom parts.
Surface-coated materials
Coated strip and materials for corrosion-protected formed parts.
Specialty materials
Specialty materials according to customer-specific requirements.
Carbide
Carbide in toolmaking, among other things machined on the carbide surface grinding machine.
Sites
Mühlacker
DEMain plant: Bernecker Umformtechnik GmbH (Plant 1 & 2) and Bernecker Engineering GmbH (toolmaking, maintenance)
- Materials
- Steels, stainless steels, light metals, coated materials
- Servo press with transfer system 8,000 kN
- Servo presses up to 4,000 kN
- Stamping press 800 t (body parts)
- 2D/3D laser equipment with 100% camera inspection
- 5-axis HSC milling centres
- EDM machines
- Grinding machines, carbide surface grinding machine
- Turning centres for hard turning
- CO₂-based HVAC assembly lines
Pausa
DEBernecker rollforming & tubes GmbH: roll-formed products and tubes
- Materials
- Metals, stainless steel
- Rollforming lines
- Servo presses up to 4,000 kN
Krušovce
SKBeShapeTech k.s.: production site for formed and machined parts
- Materials
- Metals
- Press with transfer 4,000 kN
- HSC series milling machines
- Series turning machine
- Single- and multi-spindle machines
- 3D measuring machine
- 3D scanner
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Stamped and formed parts (stamped, deep-drawn, bent, thermoformed)Forming | – | – | – | – | Light metals, Steels, Stainless steels, Surface-coated materials, High-strength materials, Non-ferrous metals, Specialty materials |
| Stamped, deep-drawn and bent parts with sheet thicknesses 0.1 mm - 6 mmForming | – | – | – | – | Metal |
| Rollforming – custom roll-formed parts and tubesForming | – | – | – | – | Metal, Stainless steel |
| Turned parts up to Ø 65 mmMachining | – | Ø 65 mm | – | – | Metal |
| Custom milled parts with tolerances below 0.01 mmMachining | < 0.01 mm | – | – | – | Metal |
| Servo press forming with transfer system, 8,000 kN press forceForming | – | – | – | – | Metal |
| Assembly of subassemblies and modulesAssembly | – | – | – | – | Metal |
| Engineering | – | – | – | – | Metal, Carbide |
| Hard turning (turning centres)Machining | – | – | – | – | Metal |
| Joining of metalsJoining | – | – | – | – | Metal |
| Laser cutting (2D and 3D, fully automatic, 100% camera inspection)Machining | – | – | – | – | Metal |
| Forming simulation and feasibility studiesEngineering | – | – | – | – | – |
| Prototypes and pre-series parts from in-house productionForming | – | – | – | – | Metal |
| 3D metrology / 3D scanning and 100% visual inspection (testing)Testing | – | – | – | – | – |
17 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Servo press with transfer system | – | 1 | 8,000 kN press force | – | Mühlacker |
| Servo presses | – | 3 | up to 4,000 kN | 2012/2018 | Mühlacker / Pausa |
| Stamping press | – | 1 | 800 t press force (body parts) | 2021 | – |
| Press with transfer | – | 1 | 4,000 kN | 2023 | Krusovce (BeShapeTech) |
| 5-axis HSC milling centres | – | – | – | – | Mühlacker (toolmaking) |
| EDM machines (electrical discharge machining) | – | – | – | – | Mühlacker (Bernecker Engineering) |
| Grinding machines | – | – | – | – | Mühlacker (toolmaking) |
| Turning centres for hard turning | – | – | – | – | Mühlacker (toolmaking) |
| Carbide surface grinding machine | – | 1 | – | 2024 | Mühlacker (Bernecker Engineering) |
| 2D and 3D laser equipment (fully automatic, 100% camera inspection) | – | – | – | 2015/2018 | – |
| HSC series milling machines | – | – | – | 2023/2024 | Krusovce (BeShapeTech) |
| Series turning machine | – | 1 | – | 2023 | Krusovce (BeShapeTech) |
| Single- and multi-spindle lathes | – | – | – | 2018 | Krusovce (BeShapeTech) |
| Lathe for tool manufacturing | – | 1 | – | 2025 | Krusovce (BeShapeTech) |
| 3D measuring machine | – | 1 | – | 2022 | Krusovce (BeShapeTech) |
| 3D scanner for series parts with evaluation software | – | 1 | – | 2024 | – |
| CO₂-based HVAC assembly lines | – | – | – | 2025 | Mühlacker (Bernecker Umformtechnik) |
Additional services
Quality & Certification
Quality assurance is based on a quality management system certified to IATF 16949 across all business areas. Inspection equipment includes fully automatic 2D/3D laser equipment with 100% camera inspection, 3D measuring machines, 3D scanners with data feedback into the CAD system as well as visual inspections.
| Evidence | Bernecker Umformtechnik GmbH (Mühlacker) | Bernecker rollforming & tubes GmbH (Pausa) | BeShapeTech k.s. (Krušovce) |
|---|---|---|---|
| IATF 16949 | |||
| ISO 9001 | |||
| ISO 14001 |
History
- 1962
Foundation of the company
- 1997
System supplier for the automotive industry with a focus on assembly and modules
- 2004
Inauguration of Plant 2 in Mühlacker (logistics, customer service, assembly, modules)
- 2006
Foundation of the subsidiary BeShapeTech k.s. in Slovakia
- 2008
Expansion of development capacity
- 2010
Entry into Profiltechnik Söll GmbH in Pausa
- 2011
Entry into the production of stainless steel tubes (Bernecker rollforming & tubes GmbH); series production of turned parts at BeShapeTech
- 2012
Acquisition of Bernecker rollforming & tubes GmbH as a 100% subsidiary; start of production with servo presses up to 4,000 kN
- 2014
New plant for BeShapeTech k.s. in Slovakia
- 2015
Deployment of fully automatic 2D and 3D laser equipment with 100% camera inspection
- 2017
Move to the new company headquarters and new plant in Mühlacker; expansion of turned parts capacity at BeShapeTech
- 2018
New laser equipment, two additional servo presses, expansion of single- and multi-spindle machine capacity at BeShapeTech
- 2019
Expansion of production capacities at BeShapeTech (buildings, machines, equipment)
- 2021
Installation of a stamping press with 800 t press force for body parts
- 2022
New 3D measuring machine and expansion of 100% camera inspection at BeShapeTech
- 2023
New HSC series milling machines, series turning machine and 4,000-kN press with transfer at BeShapeTech; new EDM machine at Bernecker Engineering
- 2024
HSC milling machines for electromobility, carbide surface grinding machine, 3D scanner for series parts
- 2025
CO₂-based HVAC assembly lines and electric motor components at Bernecker Umformtechnik; PV expansion to 457.3 kWp at Bernecker rollforming & tubes