Automation systems for high-precision manufacturing and assembly of large assemblies – from AFP to bolt fastening automation
Broetje-Automation GmbH
Rastede (DE) · Gimont (FR)New on Amplifa
About Broetje-Automation
Broetje-Automation GmbH, headquartered in Rastede, specializes in the automation of high-precision assembly and manufacturing processes. The company develops and manufactures production systems for aerospace, wind energy, shipbuilding and industrial structures, including very large components. The portfolio includes Automated Fiber Placement (AFP) systems of the STAXX family for processing prepreg, TowPreg, dry fibers, thermoplastics and thermosets, assembly cells (CPAC, IPAC, MPAC, FRAC) for drilling, milling, riveting and sealing, Torque Systems for automated bolting up to 2200 Nm as well as mobile systems such as AGVs and conveyor technology. The offering is complemented by Jigs & Tools, consulting, factory planning, retrofit, training and Smart Services with a digital machine twin. The processes are monitored by sensor systems such as SCALE and photogrammetry measurement technology. With 23 sites in 7 countries, the company supplies customers such as Airbus, Boeing, Bombardier, Siemens Gamesa and Premium AEROTEC worldwide.
- Site
- Rastede
- Processes
- Automated Fiber Placement (AFP), Preforming (Continuous Composite Preforming System CCPS), Handling/Sorting/Kitting/Draping of Composite Parts, Automated Sanding, Sealing for Corrosion Protection on Edges, Caps and Curvatures, Drilling of Various Diameters, Milling, Riveting/Fastening (automated fastening)
- Materials
- Prepreg, TowPreg, Dry Fiber, Thermoplastic, Thermoset, CFRP, Adhesives
- Certificates
- EN 9100:2018, ISO 9001:2015, ISO 14001, ISO 45001, ISO 9001, EN 9100, IATF 16949, ISO 13485
- Industries
- Aerospace, Wind Energy/Clean Energy, Shipbuilding, Composites, Industrial Structures, Automotive
- 01
Consulting & Factory Planning
- 02
Engineering & Design
- 03
Manufacturing & Machining
- 04
Robot & Systems Integration
- 05
Process Technology (AFP, Drilling, Riveting, Bolt Fastening)
- 06
Assembly & Commissioning
- 07
Smart Services & Maintenance
- 08
Academy & Training
Materials & Processes
Prepreg
Semi-finished fiber composite material with pre-impregnated resin for the Automated Fiber Placement processes of the STAXX family.
TowPreg
Resin-impregnated fiber strips for AFP processing in the STAXX One system.
Dry Fiber
Fiber material without resin carrier for handling, sorting, kitting and draping.
Thermoplastic
Formable composite materials for flexible component design and automated preforming processes.
Thermoset
Hard thermosetting materials for automated processing and ply stacking with high lay-up rates.
CFRP
Carbon fiber reinforced plastic for advanced lightweight structures in aircraft and industrial applications.
Adhesives
Joining materials used in automated joining and preforming processes.
Sites
Rastede
DEHeadquarters
- STAXX Box
- STAXX One
- STAXX Compact
- STAXX Flex
- Power RACe
- CPAC
- IPAC
- MPAC
- FRAC
- Rotary Torque System
- Stator Torque System
- Universal Carrier System
- FastPlant
- Hexagon DPA Industrial
Gimont
FRBA France – site with automation and machining team
- Expertise in mechanical design, automation, machining and tailor-made industrial solutions
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Automated Fiber Placement (AFP)Plastics | – | – | – | – | Prepreg, TowPreg, Dry Fiber, Thermoplast, Duroplast, CFK |
| Preforming (Continuous Composite Preforming System CCPS)Plastics | – | – | – | – | Composite Materials, Thermoset, Thermoplastic |
| Handling/Sorting/Kitting/Draping of Composite PartsPlastics | high positioning accuracy | – | – | – | Prepreg, Dry Fiber, Thermoset, Thermoplastic |
| Automated SandingSurface | – | – | – | – | – |
| Sealing for Corrosion Protection on Edges, Caps and CurvaturesSurface | – | – | – | – | – |
| Drilling of Various DiametersMachining | highest precision | – | – | – | – |
| MillingMachining | – | – | – | – | – |
| Riveting/Fastening (automated fastening)Joining | – | – | – | – | – |
| Automated Bolting (Torque Systems, Bolt Fastening, multi-stage up to 2200 Nm)Joining | – | – | – | – | – |
| BA Lube - Dry Lubrication with AerosolSurface | – | – | – | – | – |
| Assembly of Large Assemblies (Aerospace, Wind Energy, Shipbuilding) incl. EcoPositioner PositioningAssembly | highest precision | – | – | – | – |
| Ply Stacking for Preform Manufacturing (Lay-up Rate >100 kg/h)Plastics | – | – | – | – | Prepreg, Thermoset, Thermoplastic |
| Engineering | according to component tolerances | – | – | – | – |
| Engineering | – | – | – | – | – |
| Quality Assurance with Photogrammetry (Hexagon DPA Industrial), Mobile Measurement TeamTesting | – | – | – | – | – |
| Machining of Customized Industrial SystemsMachining | – | – | – | – | – |
22 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| STAXX Box 4-Axis Fiber Placement Machine | Broetje-Automation STAXX Box | – | Tow width 1/8'' to 2'' (50.08 mm) | – | – |
| STAXX One Single-Tow AFP Robotic System (COMAU industrial robot with rotating creel) | Broetje-Automation STAXX One | – | End effector approx. 40 kg | – | – |
| STAXX Compact AFP System | Broetje-Automation STAXX Compact | – | – | – | – |
| STAXX Flex Large Multi-Tow AFP System (up to 16 tows) | Broetje-Automation STAXX Flex | – | – | – | – |
| STAXX ONE Portable AFP System | Broetje-Automation STAXX ONE Portable | – | – | – | – |
| Power RACe Robotic System (Drilling, Riveting, Milling, three times stiffer than standard robots) | Broetje-Automation Power RACe | – | – | – | – |
| RACe Robot (Drilling/Riveting) | Broetje-Automation RACe | – | – | – | – |
| Light Robotics Cobot (mobile, collaborative) | Broetje-Automation Light Robotics | – | – | – | – |
| CPAC Clip Panel Assembly Cell (Gantry Kinematics) | Broetje-Automation CPAC | – | – | – | – |
| IPAC Integrated Panel Assembly Cell | Broetje-Automation IPAC | – | – | – | – |
| MPAC Multi-Panel Assembly Cell (Wing Covers, Fuselage Panels) | Broetje-Automation MPAC | – | – | – | – |
| FRAC Frame Clip Assembly Cell | Broetje-Automation FRAC | – | integrated in more than 30 production facilities worldwide | – | – |
| Rotary Torque System (automated bolting for wind energy) | Broetje-Automation Rotary Torque System | – | – | – | – |
| Stator Torque System (up to 2200 Nm, 5-axis) | Broetje-Automation Stator Torque System | – | – | – | – |
| Project Snowflake - Bolt Fastening Automation on AGV | Broetje-Automation Snowflake | – | – | – | – |
| EcoPositioner Positioning System | Broetje-Automation EcoPositioner | – | – | – | – |
| Universal Carrier System AGV | Broetje-Automation Universal Carrier System | – | – | – | – |
| FastPlant Conveyor System | Broetje-Automation FastPlant | – | – | – | – |
| Lift-E-50 Mobile Manipulator (up to 50 kg) | Broetje-Automation Lift-E-50 | – | – | – | UK |
| SCALE Sensor System for Process Control | Broetje-Automation SCALE | – | – | – | – |
| Hexagon DPA Industrial Photogrammetry Measurement System | Hexagon DPA Industrial | – | – | – | Rastede |
| XPAC Fastening Machine | Broetje-Automation XPAC | – | – | – | – |
Additional services
Reference customers
Quality & Certification
Quality assurance is divided into Total Quality Management and Quality Assurance and relies, among other things, on the Hexagon DPA Industrial photogrammetry measurement system as well as a mobile measurement team. Projects are executed according to Critical Chain Project Management (CCPM) with regular inspections and function tests.
| Evidence | Rastede |
|---|---|
| ISO 9001 | |
| EN 9100 | |
| ISO 14001 | |
| ISO 45001 | |
| IATF 16949 | |
| ISO 13485 |
History
- 2019-01-01
Lutz Neugebauer assumes responsibility as Managing Director of the entire Broetje Group
- 2019-03-01
Heinrich Giere becomes the new Managing Director of BA Services GmbH
- 2022-03-03
JEC World Paris: live demo of STAXX One; JEC Innovation Award as part of the TUCANA project with Jaguar Land Rover and of the IRIS Lower Wing Cover demonstrator with SPIRIT Aerosystems
- 2024-03-21
Delivery of an automated bolting machine (Torque Systems) to the Siemens Gamesa plant in Cuxhaven
- 2026-09-30
Awarded the Bombardier Diamond Award as part of the Supplier Recognition Program 2025