Development and manufacture of plastic injection-molded parts, electromechanical assemblies, surface finishing and toolmaking for automotive and industry.
ELEKTRA GmbH
Schalkau (DE) · Schalkau EOT (DE) · Łochowo (PL) · Schleusingen (DE)New on Amplifa
About ELEKTRA GmbH
Founded in 1947 and headquartered in Schalkau (South Thuringia), ELEKTRA GmbH is a development supplier and technology driver for electromechanical assemblies and high-precision individual plastic parts. The core manufacturing includes injection molding of thermoplastics and thermosets (including injection-compression cutting technology, reel-to-reel overmolding of coil-stamped parts, multi-component injection molding, silicone/elastomer processing, linked production cells) on more than 70 injection molding machines with clamping forces of up to 300 t from Arburg and Engel. Building on this, the company manufactures and assembles electromechanical assemblies on more than 40 assembly transfer lines. Elektra Oberflächentechnik GmbH (EOT) finishes plastic parts through industrial painting and laser marking in day/night design as well as black-panel/white-panel surfaces for touch displays. Two in-house tool shops design and manufacture injection molds up to 1000 x 800 mm and 3 t, including jigs and measuring equipment. The range of more than 1,800 individual products primarily serves the automotive industry (including exhaust gas aftertreatment, battery management, steering, brakes, powertrain) as well as power electronics and drive systems, including switching modules for high-current applications in wind turbines. The group employs around 750 staff at four locations in Germany and Poland and generates revenue of approximately €90 million.
- Site
- Schalkau
- Processes
- Injection molding (thermoplastic), Thermoset processing, Injection-compression cutting technology, Silicone/elastomer processing, Multi-component injection molding (up to 2 materials), Reel-to-reel injection molding (overmolding of coil-stamped parts), Linked injection molding cells with robotics, Automated assembly (assembly transfer lines, manual assembly)
- Materials
- PPS, PBT, PA, PPA, Silicone, Steel (stamped and bent parts), Brass, Bronze
- Certificates
- IATF 16949:2016, DIN EN ISO 9001, DIN EN ISO 50001:2018, IATF 16949, DIN EN ISO 50001
- Founded
- 1947
- Employees
- 750
- Industries
- Automotive, Power electronics, Drive systems, Wind power, Special machine construction (automotive, pharmaceutical, electrical, Automotive (among others environmental management/exhaust gas aftertreatment,
- 01
Product and process development
- 02
Tool design
- 03
Toolmaking
- 04
Injection molding
- 05
Surface finishing
- 06
Automated assembly
- 07
Quality inspection
Materials and Processes
Polyphenylene sulfide (PPS)
Engineering thermoplastic from the purchasing portfolio for highly heat-resistant injection-molded parts.
Polybutylene terephthalate (PBT)
Thermoplastic for electromechanical plastic components.
Polyamide (PA)
Thermoplastic for mechanically stressed plastic parts.
Polyphthalamide (PPA)
High-performance thermoplastic for demanding automotive applications.
Thermosets
Processed by injection molding, partly in cooperation with partners.
Silicone / elastomers (VMQ, FPM)
Processed on specially prepared machines; FPM and VMQ seals are also purchased.
Steel
Stamped and bent steel parts, including press-fit technology, for assembly construction.
Copper
Material for purchased stamped and bent parts.
Brass
Material for purchased stamped and bent parts.
Bronze
Material for purchased stamped and bent parts.
Locations of the Elektra Group
Schalkau (Headquarters)
DEHeadquarters of ELEKTRA GmbH: injection molding, automated assembly, toolmaking, product development
- Part weight / size
- Injection molds up to 1000 x 800 mm, max. 3 t
- Lot size
- Small series in prototype construction up to volume production
- Materials
- Thermoplastics and thermosets, silicone/elastomers
- More than 70 injection molding machines (Arburg, Engel, up to 300 t)
- More than 40 assembly transfer lines
- CNC milling center DMU 85 monoBlock
- EDM machine Form 3000 VHP
- Surface grinding machine Smartline BD10 ZRT XC
- Spot welding press TUS 80-50
- Wire-cutting and cylindrical grinding machines
- Laser welding system
- 3 painting systems
- Laser systems for day/night design
Schalkau (EOT)
DEElektra Oberflächentechnik GmbH (EOT): painting and laser marking of plastic parts
- Materials
- Plastic
- 3 painting systems
- Laser systems
- Fully automatic rocker removal and attachment machine
Łochowo (PL)
PLPol-Elektra Sp. z o.o.: production of plastic parts and electronic assemblies for the automotive industry
- Materials
- Plastic
- Injection molding machines (Arburg, Engel, up to 300 t)
Schleusingen
DEFSP-Automations GmbH: special machine construction, jigs and manual workstations
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Injection molding (thermoplastic)Plastics | – | – | – | – | Thermoplastics, PPS, PBT, PA, PPA, Silicone |
| Thermoset processingPlastics | – | – | – | – | Thermosets |
| Injection-compression cutting technologyPlastics | – | – | – | – | Thermoplastics, Metal (stamped parts/tracks) |
| Silicone/elastomer processingPlastics | – | – | – | – | Silicone, Elastomers |
| Multi-component injection molding (up to 2 materials)Plastics | – | – | – | – | Thermoplastics |
| Reel-to-reel injection molding (overmolding of coil-stamped parts)Plastics | – | – | – | – | Thermoplastics, Metal (stamped parts) |
| Linked injection molding cells with roboticsPlastics | – | – | – | – | Thermoplastics |
| Automated assembly (assembly transfer lines, manual assembly)Assembly | – | – | – | – | – |
| Assembly of electromechanical assembliesAssembly | – | – | – | – | – |
| Industrial painting of plastic partsSurface | – | – | – | – | Plastic |
| Laser marking (day/night design, black panel/white panel)Surface | – | – | – | – | Plastic |
| Toolmaking: design and manufacture of injection molds (including jigs andEngineering | – | 1000 x 800 mm | 3 t | – | Thermoplastics and thermosets |
| Toolmaking new construction: milling, turning, wire cutting, EDMMachining | – | – | – | – | – |
| Special machine construction, jigs and manual workstationsEngineering | – | – | – | – | – |
| Product and process development (CAD, simulation, prototypes)Engineering | – | – | – | – | – |
| 3D printing / rapid prototypingAdditive | – | – | – | – | – |
| Sample and prototype construction including small seriesAssembly | – | – | – | – | – |
| Measurement technology and testing (tactile/optical coordinate measuring technology, 3D scanning,Testing | – | – | – | – | – |
27 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Injection molding machines | Arburg | – | up to 300 t clamping force | – | Schalkau, Łochowo (Poland) |
| Injection molding machines | Engel | – | up to 300 t clamping force | – | Schalkau, Łochowo (Poland) |
| Injection molding machines (horizontal/vertical, rotary table) | – | more than | up to 300 t clamping force | – | Schalkau and Łochowo |
| Assembly transfer lines | – | more than | – | – | Schalkau and Łochowo |
| Painting systems | – | 3 | – | – | Schalkau |
| Laser systems | – | several | – | – | Schalkau |
| CNC milling center | DMG MORI (not explicitly stated) DMU 85 monoBlock | – | – | – | Toolmaking Schalkau |
| EDM machine | Form 3000 VHP | – | – | – | Toolmaking Schalkau |
| Surface grinding machine | Smartline BD10 ZRT XC | – | – | – | Toolmaking Schalkau |
| Spot welding press | TUS 80-50 | – | – | – | Toolmaking Schalkau |
| CNC milling centers (toolmaking) | – | – | – | – | Schalkau |
| Wire-cutting machines | – | – | – | – | Schalkau |
| EDM machines | – | – | – | – | Schalkau |
| CNC-controlled start-hole drilling machines | – | – | – | – | Schalkau |
| Cycle-controlled lathes | – | – | – | – | Schalkau |
| Cylindrical grinding machines | – | – | – | – | Schalkau |
| Tool grinding machines | – | – | – | – | Schalkau |
| Laser welding system | – | – | – | – | Schalkau |
| Ultrasonic cleaning system | – | – | – | – | Schalkau |
| Measuring machines | – | – | – | – | Schalkau |
| Tactile coordinate measuring machine | – | – | – | – | – |
| Optical coordinate measuring machine | – | – | – | – | – |
| Optical 3D scanning system | – | – | – | – | – |
| Tensile-compressive force testing machine | – | – | – | – | – |
| Climate test chamber | – | – | – | – | – |
| Thermal shock chamber | – | – | – | – | – |
| Vibration testing with climate chamber | – | – | – | – | – |
Additional services
Reference customers
Quality and Certification
All locations hold certifications according to IATF 16949 and DIN EN ISO 9001; ELEKTRA GmbH and EOT are additionally certified to DIN EN ISO 50001. Quality assurance uses tactile and optical coordinate measuring technology, 3D scanning systems, tensile-compressive force testing machines as well as climate, thermal shock and vibration testing, supported by CAQ software (IQS) with statistical process control.
| Evidence | Schalkau (Headquarters) | Schalkau (EOT) | Łochowo (PL) | Schleusingen |
|---|---|---|---|---|
| IATF 16949 | ||||
| DIN EN ISO 9001 | ||||
| DIN EN ISO 50001 |
Company History
- 1947
Founding of the home site in Schalkau, South Thuringia.
- 1990
Reorientation of competencies and product fields; followed by continuous expansion of capacities and investments.
- 1993
Foundation of the subsidiary Pol-Elektra Sp. z o.o. in Poland.
- 2004
Foundation of Elektra Oberflächentechnik GmbH (EOT) in the Schalkau industrial park.
- 2023
Integration of FSP-Automations GmbH, Schleusingen, into the Elektra corporate group; awarded the Bosch Global Supplier Award 2023.