Development and production of drive and propeller shafts for the automotive industry
IFA ROTORION - Holding GmbH
Haldensleben · Gardelegen · Irxleben · Friedrichshafen · Charleston (USA)New on Amplifa
About IFA Rotorion
IFA ROTORION - Holding GmbH, headquartered in Haldensleben (Saxony-Anhalt), develops and produces drive and propeller shafts – through-shafts, side shafts, constant velocity joints and universal joints – for passenger cars, vans, light commercial vehicles, trucks, agricultural and construction machinery. With more than 4.2 million through-shafts produced per year, the company ranks among Europe's leading propeller shaft manufacturers and supplies vehicle manufacturers worldwide, including premium manufacturers such as Porsche and Ferrari. All essential manufacturing steps are carried out in-house: friction welding and magnetic arc welding to join thin-walled steel tubes with joint components, automated final assembly, balancing, painting, and test bench runs with machine-internal quality monitoring. In addition, the company provides development services in drivetrain engineering and lightweight design, in particular with fiber composite materials for electric mobility applications. With around 1,300 employees at the Haldensleben, Gardelegen, Irxleben and Charleston (USA) sites, IFA Rotorion is one of Saxony-Anhalt's largest automotive suppliers.
- Site
- Haldensleben
- Processes
- Manufacture of drive and propeller shafts (through-shafts, side shafts, constant velocity joints,, Friction welding (joining thin-walled steel tubes with joint components), Magnetic arc welding, Assembly/final assembly of drive shafts (assembling, measuring, balancing, testing), Painting of the shafts (fully automated, defined layer thickness), EDM (electrical discharge machining) for fitting/internal gear teeth in prototype construction, Development services drivetrain engineering and lightweight design (fiber composite materials), Test bench runs (modern test benches, machine-internal quality monitoring)
- Materials
- Steel, Fiber composite materials, Electrical discharge machining (EDM)
- Certificates
- ISO 9001
- Employees
- 1,300
- Industries
- Automotive industry, Passenger cars, Vans, Light commercial vehicles, Trucks, Agricultural machinery
- 01
Development/Engineering (drivetrain engineering, lightweight design)
- 02
Friction welding of steel tubes with joint components
- 03
Magnetic arc welding
- 04
Final assembly (assembling, measuring, balancing, testing)
- 05
Painting
- 06
Test bench runs
- 07
Logistics
Materials & Processes
Steel
Thin-walled steel tubes are joined to the joint components by friction welding and magnetic arc welding.
Fiber composite materials
Used in lightweight design developments for drive shafts, among other things in the context of electric mobility.
Electrical discharge machining (EDM)
Established in prototype construction since 2016 for fast, precise production of fitting and internal gear teeth (Mitsubishi MV1200R wire EDM machine).
Sites
Haldensleben
DEHeadquarters as well as research, development and production
- Materials
- Steel, fiber composite materials
- Friction welding system
- Magnetic arc welding system
- Mitsubishi MV1200R wire EDM machine (prototype construction)
- automated final assembly and painting systems
- test benches
Gardelegen
DEProduction site
Irxleben
DEProduction site
Friedrichshafen
DEFormer seat of Rotorion GmbH; production relocated to Haldensleben
Charleston
USProduction site (Rotorion North America)
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Manufacture of drive and propeller shafts (through-shafts, side shafts, constant velocity joints,Joining | – | – | – | – | Steel |
| Friction welding (joining thin-walled steel tubes with joint components)Joining | – | – | – | – | Steel |
| Magnetic arc weldingJoining | – | – | – | – | Steel |
| Assembly/final assembly of drive shafts (assembling, measuring, balancing, testing)Assembly | – | – | – | – | – |
| Painting of the shafts (fully automated, defined layer thickness)Surface | – | – | – | – | – |
| EDM (electrical discharge machining) for fitting/internal gear teeth in prototype constructionMachining | – | – | – | – | Steel |
| Development services drivetrain engineering and lightweight design (fiber composite materials)Engineering | – | – | – | – | Fiber composite materials |
| Test bench runs (modern test benches, machine-internal quality monitoring)Testing | – | – | – | – | – |
5 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Wire EDM machine | Mitsubishi Electric MV1200R | – | – | – | Haldensleben (prototype construction) |
| Friction welding system | – | – | – | – | Haldensleben |
| Magnetic arc welding system | – | – | – | – | Haldensleben |
| Test benches | – | – | – | – | Haldensleben |
| Automated final assembly/painting systems | – | – | – | – | Haldensleben |
Additional services
Reference customers
Quality
Every manufacturing step is monitored for quality machine-internally; final assembly includes measuring, balancing and testing. Modern test benches and test engineers ensure reliable, traceable test results.
| Evidence | Haldensleben |
|---|---|
| ISO 9001 |
History
- 1992
Privatization of the IFA state-owned enterprise by Heinrich von Nathusius
- 2008
Registration of Rotorion GmbH in Friedrichshafen (Ulm District Court HRB 722302); founded by MTU Friedrichshafen (Tognum)
- 2009
Acquisition of Rotorion GmbH (propeller shaft division of Tognum AG) by IFA; merger with Rotorion GmbH from Friedrichshafen
- 2010
Merger into IFA ROTORION - Powertrain GmbH in Haldensleben; operating as IFA ROTORION - Holding GmbH since October 2010; deletion of Rotorion GmbH on 28.04.2010
- 2010
Annual revenue of the IFA Group around 350 million euros
- 2016
Establishment of EDM technology in the prototype construction of the IFA Group