Development and series production of customized acoustic insulation solutions based on polyurethane, more than 1 million dash panels per year
Dr. Freist Automotive Bielefeld GmbH
Bielefeld (Headquarters) · GoslarNew on Amplifa
About DFA Bielefeld
Dr. Freist Automotive Bielefeld GmbH (DFA) is a medium-sized family-owned company based in Bielefeld, specializing in the development and manufacture of acoustic insulation products – primarily for the automotive industry. The products are based on polyurethane (PUR): as acoustic protection foam, as a biocompatible material for medical products, and as a basis for industrial hotmelt adhesives. Using THL technology (Tailored Heavy Layer), weight- and function-optimized sound insulation parts are produced from PUR foam and heavy foil; the meltblown technology produces microfiber absorber nonwovens under the SONOZORB B brand. Processing methods include extrusion, calendering, deep drawing, foaming, injection molding, spraying, cold/hot pressing, punching/die cutting, waterjet cutting and RF welding. Proprietary PUR formulations are developed in the company's own materials laboratory; an acoustics laboratory characterizes materials, semi-finished products and finished components. With more than 260 employees and an annual capacity of more than 1 million dash panels, the company supplies a significant share of demand, particularly for the Volkswagen Group, and also serves the household appliance and construction industries.
- Site
- Bielefeld
- Processes
- Extrusion, Calendering, Deep drawing, Foaming, Injection molding, Spraying, Cold/hot pressing, Die cutting/punching
- Materials
- Polyurethane (PUR), PP, EPDM, PET, Aluminum, Basalt wool, Glass wool, BW (nonwoven)
- Certificates
- EN 14683:2019+AC:2019 (Sono MN E5, Type II) testing of medical face masks, EN 14683 (Sono MN E5, Type II) – tested by HygCen Austria
- Employees
- more than 260
- Industries
- Automotive industry, Household appliance industry, Construction industry, Medical technology/medical products
- 01
Material development (proprietary PUR formulations in the materials laboratory)
- 02
Technical center with pilot plants
- 03
Extrusion, calendering, foaming
- 04
Pressing, punching, waterjet cutting, RF welding
- 05
Acoustic measurement in own laboratory
- 06
Series production
- 07
Delivery to automotive OEMs
Materials and Processes
Polyurethane (PUR)
Base material for acoustic protection foams, insulation, adhesives and medical products.
THL Technology (Tailored Heavy Layer)
Weight- and function-optimized sound insulation made of PUR foam and heavy foil.
Meltblown Technology (SONOZORB B)
Production of microfiber absorber nonwovens for airborne sound absorption in exterior and interior applications.
Plastics (PP, EPDM, PET)
Nonwovens and plastics for absorber, insulation and isolation components, also in combination with aluminum.
Mineral wools (basalt and glass wool)
Nonwoven materials for acoustic and thermal insulation applications.
Aluminum
Processed in combination with nonwovens and plastics for insulation components.
Hotmelt adhesives (1K-PUR 'PurReact')
Flexibly available 1K-PUR adhesive for industrial bonding applications.
Locations
Bielefeld
DEHeadquarters, development and series production
- Lot size
- High-volume series (more than 1 million dash panels/year)
- Materials
- PUR, PP, EPDM, PET, nonwovens, heavy foil, aluminum
- State-of-the-art, in-house designed production lines
- Robot-assisted presses
- Die cutting/punching
- Pilot plants in own technical center
- Materials and acoustics laboratory
Goslar
DELocation of Dr. Freist Automotive GmbH
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| ExtrusionPlastics | – | – | – | – | Polyurethane, PP, EPDM, PET, Aluminum |
| CalenderingPlastics | – | – | – | – | Polyurethane, PP, EPDM, PET, Aluminum |
| Deep drawingForming | – | – | – | – | Polyurethane, PP, EPDM, PET, Aluminum |
| FoamingPlastics | – | – | – | – | Polyurethane |
| Injection moldingPlastics | – | – | – | – | Polyurethane, PP, EPDM |
| SprayingPlastics | – | – | – | – | Polyurethane |
| Cold/hot pressingForming | – | – | – | – | Polyurethane |
| Die cutting/punchingForming | – | – | – | – | Polyurethane, Nonwovens (BW, PP, PET, basalt wool, glass wool), Aluminum |
| Waterjet cuttingMachining | – | – | – | – | Polyurethane, Nonwovens, Aluminum |
| RF weldingJoining | – | – | – | – | Polyurethane, Plastics |
| Meltblown technology (production of microfiber absorber nonwovens, SONOZORB B)Plastics | – | – | – | – | Polyurethane, PP, PET |
| THL technology (Tailored Heavy Layer) – sound insulation made of PUR foam and heavy foilPlastics | – | – | – | – | Polyurethane foam, Heavy foil |
| Production of acoustic insulation products (dash panels, interior)Plastics | – | – | – | Series (1 million dash panels/year) | Polyurethane, Nonwovens, Aluminum |
| Hotmelt adhesives (1K-PUR adhesive 'PurReact')Joining | – | – | – | – | Polyurethane |
| Materials and acoustics laboratory: characterization of materials, semi-finished products andTesting | – | – | – | – | Polyurethane, Nonwovens, Plastics, Aluminum |
4 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| State-of-the-art production lines (in-house design) | – | – | – | – | Bielefeld |
| Die cutting/punching machines | – | – | – | – | Bielefeld |
| Robot-assisted presses | – | – | – | – | Bielefeld |
| Pilot plants in the technical center | – | – | – | – | Bielefeld |
Additional services
Reference customers
Quality and Certificates
DFA Bielefeld has its own materials laboratory for the characterization of foams, nonwovens and plastics, as well as an acoustics laboratory with all essential measuring equipment for materials, semi-finished products and finished components. The company is certified; the medical face mask Sono MN E5 (Type II) was successfully tested in accordance with EN 14683:2019+AC:2019.
| Evidence | Bielefeld |
|---|---|
| EN 14683 (Sono MN E5, Type II) – tested by HygCen Austria |
History
- 2012
Series launch of products for the VW Golf 7
- 2013
Volkswagen Group Award 2013 as one of 21 suppliers worldwide; the only locally based award winner
- 2020
Testing of the medical face mask Sono MN E5 (Type II) in accordance with EN 14683:2019+AC:2019 by HygCen Austria