Turnkey production systems and automation systems for automotive, aerospace and industry since 1974.
FFT Produktionssysteme GmbH & Co. KG
Fulda · Mücke · Schmalkalden · Eisenach · Bremen · Augsburg · Weingarten · Petersberg · Silla (Valencia) · Bilzen-Hoeselt · Campulung · KatowiceNew on Amplifa
About FFT Produktionssysteme
FFT Produktionssysteme is an international provider of automated and flexible manufacturing systems headquartered in Fulda. As a turnkey specialist, the company develops, plans and implements turnkey production systems for the automotive, aerospace and rail industries as well as general industry – from concept development and engineering with virtual commissioning through to assembly, commissioning and after-sales support. Core competencies include body-in-white, final assembly, battery assembly, bonding technology, filling technology, folding and laser technology, welding and joining technology, lightweight construction with CFRP as well as optical metrology and battery testing. In addition, the group offers prototype and tool making as well as sheet metal forming through FFT Werkzeug + Karosserie in Eisenach. With 24 locations worldwide and 2,518 employees, FFT achieved a total output of 844.83 million euros in 2025.
- Site
- Fulda
- Processes
- Bonding (semi-/fully automatic bonding systems, stationary or robot-guided), Filling technology (filling systems for liquids and gases in final vehicle assembly), Folding technology / roller hemming technology, Laser technology (cutting, welding, processing), Welding and joining technology (resistance spot welding, MIG/MAG, projection welding), Lightweight construction (CFRP filament winding / FibreTEC, robot-guided fiber placement), Metrology / optical 3D quality control (gap and flush measurement, ShapeScan, BeadControl), Through-light inspection of components (material defect detection)
- Materials
- 1K PU, 2K PU, Butyl adhesive, Hot-melt adhesives, PVC, Epoxy resins, Polyurethane, Rubbers
- Certificates
- DIN EN ISO 9001:2015, EN/AS 9100:2018, VDA 6.4, ISO 14001:2015, ISO 45001:2018, ISO 50001:2018, TISAX assessment, BSFZ seal, Seal of quality "Innovative through Research", ISO 9001, EN 9100, ISO 14001, ISO 45001, ISO 50001
- Founded
- 1974
- Employees
- 2518
- Industries
- Automotive (OEMs and suppliers), Aviation/aerospace industry, Rail industry, Trucks, General Industry, Battery production and recycling
- 01
Concept development and factory planning
- 02
Engineering and virtual commissioning
- 03
Robot programming and simulation
- 04
Mechanical production and fixture construction
- 05
Cell production and complete assembly of production systems
- 06
On-site commissioning
- 07
After-sales service (maintenance, spare parts, repairs)
Materials and Processes
1K/2K Polyurethane
Adhesives for semi- and fully automatic bonding systems in body-in-white.
Epoxy resins
High-viscosity adhesives and sealants, processable in RAM presses and dosing units.
PVC
Material for adhesive and sealant applications in vehicle assembly.
Silicones
Adhesives and sealants for automated application processes.
Acrylates
Processable adhesive group for industrial bonding applications.
CFRP (carbon fiber composite)
Filament winding and robot-guided fiber placement for lightweight profiles, grippers and structural components.
Aluminum
Material for lightweight profiles and connections in the FFT Lightweight modular system.
Steel alloys
Joining basis for resistance spot welding with FFT welding guns.
Locations
Fulda
DEHeadquarters; complete assembly of production systems, project management center, technology center
- Assembly halls (15,000 m²)
Mücke
DEMechanical production, gripper manufacturing and assembly, bonding systems and filling technology, cell production and
- RAM presses / drum pumps for adhesives and sealants (20–1,000 l)
- Electric dosing units EMU (18–900 cm³, 300 bar)
Schmalkalden
DEMechanical production, fixture manufacturing and assembly, cell production
- Assembly area 6,300 m²
- Mechanical production 1,450 m²
Eisenach
DEFFT Werkzeug + Karosserie GmbH: forming and joining technology, prototype and tool making, tool repair and maintenance
- Lot size
- Prototype, small series
- Materials
- Steel, aluminum
Bremen
DETurnkey testing systems for aerospace and automotive; testing for e-mobility and hydrogen
- FFTtesting eFlexMobile (mobile testing unit up to 10 kW)
- In-house testing and calibration fixtures
Augsburg
DEWelding and joining technology, welding guns and accessories
- Materials
- Steel alloys
- FFTweldtec Basic C-, X- and XL-type welding guns
Silla (Valencia)
ESProject and technology center for the Iberian market; MAG welding systems, prototype center
- MAG prototype center with laboratory
- CNC measuring center
- Projection welding machines
Campulung
ROManufacturing site for fixtures, grippers, robot mounts and cap changers
- Assembly area 4,000 m²
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Bonding (semi-/fully automatic bonding systems, stationary or robot-guided)Joining | – | – | – | – | 1K PU, 1K PU with booster, 2K PU, Butyl adhesive, Hot-melt adhesives |
| Filling technology (filling systems for liquids and gases in final vehicle assembly)Assembly | – | – | – | – | – |
| Folding technology / roller hemming technologyForming | – | – | – | – | – |
| Laser technology (cutting, welding, processing)Joining | – | – | – | – | – |
| Welding and joining technology (resistance spot welding, MIG/MAG, projection welding)Joining | – | – | – | – | Steel alloys, Aluminum alloys |
| Lightweight construction (CFRP filament winding / FibreTEC, robot-guided fiber placement)Plastics | – | – | – | – | CFRP, Carbon fibers, Aluminum |
| Testing | – | – | – | – | Battery modules, Battery packs |
| Metrology / optical 3D quality control (gap and flush measurement, ShapeScan, BeadControl)Testing | – | – | – | – | – |
| Through-light inspection of components (material defect detection)Testing | – | – | – | – | – |
| Assembly and production systems (body-in-white, final assembly, FAL, battery assembly)Assembly | – | – | – | – | – |
| Turnkey partnership / turnkey production systemsEngineering | – | – | – | – | – |
| Robot programming (online/offline: Process Simulate, Delmia, Roboguide, RobotStudio, WorkVisual)Engineering | – | – | – | – | – |
| Prototype production and small series (sheet metal forming through to car body)Assembly | – | – | – | – | – |
| Painting system automationSurface | – | – | – | – | – |
| Material bond hemming fixation (VarioPicker® EVO)Joining | – | – | – | – | Sheet metal parts |
10 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Drum pump / RAM press for adhesives and sealants | FeRe (FFT group) | – | – | – | Mücke |
| Electric dosing unit (EMU series) | FeRe (FFT group) EMU | – | Dosing volume 18–900 cm³, 300 bar | – | – |
| Welding gun (C-, X-, XL type) for steel alloys | FFT FFTweldtec Basic | – | – | – | Augsburg |
| Automated guided vehicle with lifting table (up to 1 t) | FFT FFTigv ELEVATE 1t | – | – | – | – |
| Laser scanner (3D) | FFT FFT Blue / VarioQuad | – | – | – | – |
| Triangulation/dual-head/area/linear sensors for gap, flush and hole measurement | FFT VarioGauge VG7 LL / VG6 2.5D / DH / VG7 2D | – | – | – | – |
| Mobile testing unit for battery modules/packs | FFT FFTtesting eFlexMobile | – | Load capacity up to 10 kW | – | Bremen |
| Through-light inspection system | FFT FFTmetrology CheckThrough | – | – | – | – |
| 3D measuring system for bond seam control (measuring frequency 200 Hz, sensor resolution 0.05 mm) | FFT FFTmetrology BeadControl | – | – | – | – |
| Electromechanical lightweight clamp (~3.5 kg, clamping tolerance ±0.05 mm) | FFT FFTlightweight Clamp | – | – | – | – |
Additional services
Reference customers
Quality
Quality management covers all locations and is supported by certified management systems according to ISO 9001, EN 9100, VDA 6.4, ISO 14001, ISO 45001 and ISO 50001 as well as a TISAX assessment. In-house testing technologies such as optical 3D metrology, through-light inspection and bond seam control ensure process and product quality.
| Evidence | Fulda | Mücke | Schmalkalden |
|---|---|---|---|
| ISO 9001 | |||
| EN 9100 | |||
| ISO 14001 | |||
| ISO 45001 | |||
| ISO 50001 |
History
- 1974
Takeover of the corrugating machine factory in Mücke by Gerhard Faust, Horst Eckard and Bruno Frey; founding as Faust Fertigungstechnik GmbH & Co. KG.
- 1978
Construction of a new assembly hall (1,000 m²) in Mücke.
- 1981
Patenting of the first automatic system for positioning and gluing windows onto car bodies.
- 1984
Second assembly hall (1,000 m²) and office building (2,000 m²) in Mücke.
- 1987
Gerhard Faust sells his shares; Reinhold Schiele takes over management; renamed FFT Flexible Fertigungstechnik GmbH & Co. KG.
- 2005
Establishment of the Campulung location (Romania).
- 2022
Integration of FeRe Dosier- und Klebsysteme GmbH into the FFT group.
- 2025
Total output 844.83 Mio. €, 2,518 employees, 24 locations worldwide.