Manufacturing of PUR foam moulded parts, upholstery components and conversion of technical textiles for automotive, medical and office applications
Pi-Concept GmbH
AmbergNew on Amplifa
About Pi-Concept
Pi-Concept GmbH was founded in 2001 in Amberg/Upper Palatinate and is an owner-managed system supplier of polyurethane foam moulded parts, upholstery components and converted products made from technical textiles. Its service portfolio includes PUR foaming, including overmoulding of components and sensor technology, industrial sewing, upholstery, leather covering, ultrasonic welding and PU painting. Parts are produced in flexible foam, integral foam as well as semi-rigid and rigid foam with hardness levels from 15 to 85 Shore A, in open-cell or closed-cell structure and in a variety of colours; foam moulded parts are also produced with integrated sensors, switches or inserts made of plastic, wood and metal. Customers come from automotive, medical technology/healthcare, wellness/cosmetics, office, vehicle care and handling/packaging, predominantly in Europe. At the Amberg site, near the A6 motorway, 45 employees produce on 1,100 m² of production space – with approximately 400,000 shots per year, more than 100,000 upholstery parts annually and 70,000 sewing minutes per month. Development supports products from the initial idea through to series production.
- Site
- Amberg
- Processes
- PUR foaming (foam moulded parts, overmoulding of components and sensor technology), Overmoulding of components (sensors, switches, inserts made of plastic, wood or metal), Sewing/Joining/Bonding (industrial sewing, bonding and joining of technical textiles), Upholstering (medical positioning aids, automotive interior components), Leather covering (leather-worked handles, panels, armrests), Ultrasonic welding (tool-based manufacturing or free-form welding), PU painting (seamless sealing, elastic skin coating, selectable layer thickness), Cutting (die-cut, machine-cut or laser-cut blanks)
- Materials
- Polyurethane (PUR), PU foam systems (flexible foam, integral foam, semi-rigid/rigid foam; hardness 15–85 Shore A), PU-coated base fabrics, Leather, Synthetic leather, Plush, High-pile, Technical textiles
- Certificates
- ISO 9001:2015, ISO 9001, OEKO-TEX (on request, customer-specific)
- Founded
- 2001
- Employees
- 45
- Industries
- Automotive, Medical technology/Healthcare, Wellness/Cosmetics, Office, Vehicle care, Handling/Packaging
- 01
Development/Design
- 02
Cutting (die-cutting, cutting machines, laser)
- 03
PUR foaming/overmoulding
- 04
Sewing/Joining/Bonding
- 05
Upholstery/Leather covering
- 06
Ultrasonic welding
- 07
PU painting
- 08
Quality inspection
- 09
Storage/Shipping
Materials and Processes
PUR flexible foam
Open-cell or closed-cell polyurethane flexible foam for upholstery and foam moulded parts in various densities.
PUR integral foam
Integral foam with a dense outer skin for handles, panels and visible moulded parts.
PUR semi-rigid/rigid foam
Semi-rigid and rigid PU foams up to 85 Shore A, among other things for energy absorbers in the automotive sector.
PU-coated base fabrics
Coated cover materials for industrial sewing and conversion of technical textiles.
Leather
Processing for leather covering of handles, panels and armrests in the premium automotive sector.
Synthetic leather
Cover material for upholstery parts in automotive, medical technology, wellness and office applications.
Plush/High-pile
Textile cover materials for upholstery and cosmetic products.
Thermoplastics
Single- or multi-layer welding by ultrasonics, among other things for protective covers and belts.
Wood/metal inserts
Overmoulded inserts made of wood or metal for integrating fasteners and functional components.
Site
Amberg
DEProduction, Administration, Warehouse
- Lot size
- Small batch sizes to large-scale series (approx. 400,000 shots/year)
- Materials
- PUR foams, technical textiles, leather/synthetic leather, thermoplastics
- 4 foaming machines, 2 of which with colour nozzles for through-coloured parts
- 2 ultrasonic welding systems, including 1 welding automation line for medical products
- PU painting system
- Sewing shop with modern machine fleet
- More than 1,000 storage slots
Product Examples
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| PUR foaming (foam moulded parts, overmoulding of components and sensor technology)Plastics | – | – | – | small batch sizes – large-scale series (approx. 400,000 | Polyurethane (PUR) – flexible foam, integral foam, |
| Overmoulding of components (sensors, switches, inserts made of plastic, wood or metal)Plastics | – | – | – | – | Polyurethane (PUR), Plastic, Wood, Metal |
| Sewing/Joining/Bonding (industrial sewing, bonding and joining of technical textiles)Joining | – | – | – | 70,000 sewing minutes per month; >30,000 | PU-coated base fabrics, Leather, Synthetic leather, Plush, High-pile, Plastics |
| Upholstering (medical positioning aids, automotive interior components)Joining | – | – | – | more than 100,000 upholstery parts per | Synthetic leather, Leather, PU materials |
| Leather covering (leather-worked handles, panels, armrests)Joining | – | – | – | – | Leather |
| Ultrasonic welding (tool-based manufacturing or free-form welding)Joining | – | – | – | more than 2 million parts produced | Thermoplastics, Technical textiles |
| PU painting (seamless sealing, elastic skin coating, selectable layer thickness)Surface treatment | – | – | – | – | PU paint on PUR moulded parts and complex-shaped parts |
| Cutting (die-cut, machine-cut or laser-cut blanks)Machining | – | – | – | – | Textiles, Leather, Synthetic leather, PU materials |
| Development and product development (from the idea to series production)Engineering | – | – | – | – | – |
8 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Foaming machine | – | 2 | – | 2008 | Amberg |
| Foaming machine | – | 1 | – | 2014 | Amberg |
| Foaming machine with colour nozzles (through-coloured parts) | – | 1 | – | 2019 | Amberg |
| Colour foaming machine | – | 1 | – | 2023 | Amberg |
| Ultrasonic welding system | – | 1 | – | 2009 | Amberg |
| Ultrasonic welding automation line (for medical products) | – | 1 | – | 2021 | Amberg |
| PU painting system (PU paint shop for medical products) | – | 1 | – | 2017 | Amberg |
| Sewing machines (modern machine fleet in the sewing shop) | – | – | – | – | Amberg |
Additional services
Quality Management
Pi-Concept maintains quality management across all stages of the manufacturing process and is certified in accordance with DIN EN ISO 9001:2015. For foam moulded parts, indentation hardness tests are documented; in ultrasonic welding, the manufacturing processes are monitored and documented; for customer products, OEKO-TEX certification can be obtained on request.
| Evidence | Amberg |
|---|---|
| ISO 9001 | |
| OEKO-TEX (on request, customer-specific) |