Development and manufacturing of exhaust systems, battery housings and hydrogen tank systems for passenger cars, commercial vehicles and off-highway applications
Friedrich Boysen GmbH & Co. KG
Altensteig · Nagold · Simmersfeld · Achim · Plauen · Salching · Kösching · Heubach · Algolsheim · Subotica · Shenyang · Langfang · Tianjin · Six October City · Surajpur · Pune · East London · GaffneyNew on Amplifa
We are Boysen
The Friedrich Boysen GmbH & Co. KG is a foundation-owned company and system partner to the automotive and commercial vehicle industry, headquartered in Altensteig (Northern Black Forest). Its core business covers the development and manufacture of exhaust manifolds, catalytic converters, particulate filters, mufflers, exhaust valves, tailpipe trims and complete exhaust systems for passenger cars, commercial vehicles and off-highway applications. Since 2016 the company has been gradually transforming into new business areas: since 2025 battery housings for electric vehicles have been produced in large-scale series, and Boysen is also developing hydrogen tank systems (sLH2 and CGH2), fuel cell applications and redox-flow energy storage systems. Manufacturing includes laser welding, laser-hybrid and friction stir welding, hydroforming, deep drawing, CNC machining as well as KTL, powder and PVC coating; materials are primarily steel, stainless steel and aluminium. With three development centres in Altensteig, Nagold and Simmersfeld and around 30 production sites worldwide, Boysen supplies among others Audi, BMW, Mercedes-Benz, Porsche, Volkswagen, Daimler Truck and MAN, also as a JIS sequenced supplier directly to the vehicle plants.
- Site
- Altensteig
- Processes
- Manufacture of complete exhaust systems just-in-sequence (JIS), Manufacture of pipe bends, Manufacture of catalytic converters, Manufacture of particulate filters (gasoline and diesel particulate filters), Manufacture of mufflers, Manufacture of exhaust valves, Tailpipe trim manufacturing, Manufacture of battery housings (aluminium extruded profiles, steel deep-drawn parts)
- Materials
- Steel, Stainless steel, Aluminium (extruded profiles, die castings, deep-drawn sheets), Ceramics (catalytic converter/filter substrates), Metal substrates (catalytic converters), Stainless Steel, Aluminium, Ceramics
- Certificates
- DIN EN ISO 9001, IATF 16949:2016, ISO 14001, EMAS, TISAX (VDA ISA), EN 15085 (welding of rail vehicles), DIN EN ISO 3834-2, Ecovadis sustainability certificate, ISO 9001, IATF 16949, ISO 45001, TISAX, EN 15085
- Founded
- 1921
- Employees
- 5100
- Industries
- Automotive industry (passenger cars, premium), Commercial vehicles, Off-highway (rail vehicles, agricultural and construction machinery, marine), Electromobility, Hydrogen technology, Energy storage
- 01
Development and Design
- 02
Simulation and Testing
- 03
Prototype Construction
- 04
Forming (Pressing, Bending, Deep Drawing, Hydroforming)
- 05
Joining (Welding, Brazing, Bonding)
- 06
Canning/Packing of Catalytic Converters and Filters
- 07
Coating (KTL, Powder, PVC)
- 08
Assembly of Complete Systems
- 09
Testing and Metrology
- 10
JIS Logistics to Vehicle Plants
Materials and Processes
Steel
Base material for exhaust systems, structural components and steel deep-drawn parts of battery housings.
Stainless Steel
For thermally and corrosion-stressed exhaust components as well as hydrogen tank systems.
Aluminium
Extruded profiles, die castings and deep-drawn sheets, in particular for battery housings and structural components of electric vehicles.
Ceramics
Substrate material in catalytic converters and particulate filters.
Products and Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Manufacture of complete exhaust systems just-in-sequence (JIS)Assembly | – | – | 1.3 tonnes (exhaust aftertreatment | – | Steel, Stainless steel, Aluminium |
| Manufacture of pipe bendsJoining | – | – | – | – | Steel, Stainless steel |
| Manufacture of catalytic convertersAssembly | – | – | – | – | Ceramics, Metal substrates |
| Manufacture of particulate filters (gasoline and diesel particulate filters)Assembly | – | – | – | – | Ceramics, Metal |
| Manufacture of mufflersAssembly | – | – | – | – | Steel, Stainless steel |
| Manufacture of exhaust valvesAssembly | – | – | – | – | Steel, Stainless steel |
| Tailpipe trim manufacturingMachining | – | – | – | – | Steel, Stainless steel |
| Manufacture of battery housings (aluminium extruded profiles, steel deep-drawn parts)Joining | – | – | – | up to 1,000 units/day (from 2025, group) | Aluminium, Steel, Stainless steel |
| Manufacture of structural components for electric vehiclesJoining | – | – | – | – | Aluminium, Steel |
| Manufacture of hydrogen tank systems (sLH2 and CGH2)Assembly | – | – | – | – | Stainless steel |
| Manufacture of motorcycle framesJoining | – | – | – | – | Steel, Aluminium |
| Electrode manufacturing for redox-flow batteriesEngineering | – | – | – | – | – |
| Laser-hybrid weldingJoining | – | – | – | – | Aluminium, Steel |
| Friction stir weldingJoining | – | – | – | – | Aluminium |
| Spot and stud weldingJoining | – | – | – | – | Steel, Aluminium |
| Bonding and milling processes (fully automated)Joining | – | – | – | – | Aluminium, Steel |
| KTL, powder and PVC coatingSurface | – | – | – | – | Steel, Aluminium, Stainless steel |
| Laser welding technology for manifolds and mufflersJoining | – | – | – | – | Steel, Stainless steel |
| Brazing technology (exhaust manifolds)Joining | – | – | – | – | Steel, Stainless steel |
| HydroformingForming | – | – | – | – | Steel, Aluminium |
| Tailored pipes in laser technologyJoining | – | – | – | – | Steel, Stainless steel |
| Tube manufacturing using HF technologyForming | – | – | – | – | Steel, Stainless steel |
| Roll-forming technologyForming | – | – | – | – | Steel |
| Plasma welding technology for mufflersJoining | – | – | – | – | Steel, Stainless steel |
| Transfer stage pressesForming | – | – | – | – | Steel, Aluminium |
| CNC sheet metal processingMachining | – | – | – | – | Steel, Stainless steel, Aluminium |
| High-speed milling (component machining)Machining | – | – | – | – | Aluminium, Steel |
| Winding technology for mufflers and catalytic convertersForming | – | – | – | – | Steel, Stainless steel |
| Packing technology for catalytic convertersAssembly | – | – | – | – | Ceramics, Metal substrates |
| Canning of catalytic convertersAssembly | – | – | – | – | Ceramics, Metal substrates |
| Tube bending (CNC, single- and double-wall)Forming | – | – | – | – | Steel, Stainless steel |
| Laser cutting (5-axis)Machining | – | – | – | – | Steel, Stainless steel, Aluminium |
| MAG, TIG and laser weldingJoining | – | – | – | – | Steel, Stainless steel, Aluminium |
| Stamped and drawn parts manufacturing (press shop)Forming | – | – | – | – | Steel, Aluminium |
| Manufacture of stamped and pressed parts, tubes and catalytic converter cartridgesForming | – | – | – | Small series up to 200 – 200,000 units/year | Steel, Stainless steel |
| Prototype construction under series conditionsEngineering | – | – | – | – | – |
| Testing of exhaust systems (hot shake test benches, hot gas generators)Testing | – | – | – | – | – |
| 3D printing for prototype manufacturingAdditive | – | – | – | – | – |
| Leak and dimensional testing in automatic measuring cellTesting | – | – | – | – | – |
| Insulation assembly (air-gap insulated manifolds)Assembly | – | – | – | – | – |
35 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Fully automatic laser processing centre | – | 1 | – | – | Altensteig (Turmfeld) |
| 5-axis laser cutting system | – | 1 | – | – | Altensteig (Turmfeld) |
| 10-kW flatbed laser (diode-pumped disk laser) | – | 1 | – | – | Altensteig (Turmfeld) |
| CNC-controlled bending machines | – | – | – | – | Altensteig (Turmfeld) |
| Tailored tubes welding system | – | 1 | – | – | Altensteig (Turmfeld) |
| Gantry welding system | – | 1 | – | – | Altensteig (Turmfeld) |
| Canning systems for passenger car catalytic converters | – | 2 | – | – | Altensteig (Turmfeld) |
| Hot-end production lines | – | 4 | – | – | Altensteig (Turmfeld) |
| Automatic measuring cell (leak and dimensional testing) | – | 1 | – | – | Altensteig (Turmfeld) |
| Hot shake test benches | – | 2 | – | – | Altensteig (EDC) |
| Vehicle roller dynamometer for commercial vehicles | – | – | – | – | Nagold (BIN) |
| 3D printer (prototypes) | – | – | – | – | Nagold (BIN) |
| Engine test bench with acoustic chamber | – | – | – | – | Nagold (BIN) |
| Multi-axis test bench (durability testing of commercial vehicles) | – | – | – | – | Nagold (BIN) |
| Bending fatigue test bench | – | – | – | – | Nagold (BIN) |
| Test benches for hydrogen tank systems | – | – | – | – | Nagold (BIN) |
| Fuel cell test rigs (single cells and stacks) | – | – | – | – | Simmersfeld (BAK development centre) |
| Walk-in climate and corrosion chamber | – | – | – | – | Simmersfeld (BAK development centre) |
| Canning systems for catalytic converters | – | – | – | – | Achim |
| CNC tube bending machines | – | – | – | – | Achim |
| ACB canning systems for oval and round catalytic converters, SCR canning | – | – | – | – | Simmersfeld (BAK I) |
| Automatic measuring cells | – | 2 | – | – | Simmersfeld (BAK I) |
| Presses (BAK press shop) | – | – | – | 2004 | Simmersfeld (Press shop) |
| 500 t hydraulic press | – | 1 | – | – | Six October City (Egypt) |
| CNC bending machine with robot feeding | – | – | – | – | Six October City (Egypt) |
| CNC-controlled bending machines for tube manufacturing | – | – | – | – | Shenyang I |
| Canning systems for gasoline particulate filter production | – | – | – | – | Shenyang II |
| 1,000 t servo presses | – | 2 | – | – | Langfang |
| Large presses (2,000 t and 630 t) | – | 2 | – | – | Tianjin |
| Fully automatic canning system for catalytic converters | – | 1 | – | – | Tianjin |
| Large press 2,000 t | – | 1 | – | – | Subotica |
| High-speed milling centre (up to 150 m/min; 15 m/s²) | – | – | Speed up to 150 m/min; acceleration up to 15 m/s² | 2021 | – |
| Fully automated laser cell for manufacturing of plate evaporators | – | – | – | 2018 | – |
| Fully automated assembly system for exhaust valves | – | – | – | 2022 | – |
| Fully automated production line for rear mufflers | – | 1 | – | – | Plauen |
Additional services
Quality
The quality management system complies with DIN EN ISO 9001 and IATF 16949:2016; testing equipment includes automatic measuring cells for leak and dimensional testing, test benches for testing and fully automated optical measurement. Several plants are additionally certified to ISO 14001, EMAS, TISAX (VDA ISA), EN 15085 and DIN EN ISO 3834-2.
| Evidence | Altensteig | Nagold | Achim | Plauen | Salching |
|---|---|---|---|---|---|
| ISO 9001 | |||||
| IATF 16949 | |||||
| ISO 14001 | |||||
| ISO 45001 | |||||
| TISAX | |||||
| EN 15085 |
Company History
- 1921
Founded by Friedrich A. Boysen in Leipzig (Steigboy Apparatebau GmbH), exhaust mufflers for cars, motorcycles and aircraft
- 1930
Company insolvency during the Great Depression
- 1945
Re-establishment in Stuttgart
- 1949
Relocation of production to Altensteig
- 1972
Production start at Turmfeld I plant
- 1993
World's first on-site assembly plant in Salching for JIS production of complete exhaust systems
- 1996
Establishment of the Friedrich and Elisabeth Boysen Foundation
- 1998
First foreign subsidiary, Boysen France
- 2007
Market entry into China
- 2016
Start of technological transformation (battery housings, hydrogen, energy storage)
- 2021
The Foundation becomes sole shareholder; structural components for electric vehicles
- 2024
Completion of the Simmersfeld development centre and start of construction of the BBKN plant in Nagold
- 2025
Series production of battery housings at two locations; 30 locations worldwide, around 5,100 employees