EMPT machine systems for electromagnetic welding, joining and forming in industrial series production
PSTproducts GmbH
Alzenau (DE) · Wuxi (CN)New on Amplifa
About PSTproducts
PSTproducts GmbH, headquartered in Alzenau, is a manufacturer of machine systems based on Electromagnetic Pulse Technology (EMPT). The systems consist of BlueWave series pulse generators and material-specific coils and enable contactless welding, joining, forming and burr-free cutting of electrically conductive workpieces with a process time of around 25 µs without significant heat input. Among other things, this allows multimaterial joints such as aluminium-copper as well as distortion-free seams on thermally sensitive aluminium alloys to be produced. The portfolio covers EMPT machine systems, tooling coils (tube compression, tube expansion, flat welding and multi-joining coils), automation and turnkey systems with robot, rotary table and transfer belt solutions, as well as engineering and prototyping with FEM simulation. The main applications are in battery production, e-mobility, sheet metal and tube applications, and pharmaceutical packaging technology. Since 2022, the family-owned company has maintained a subsidiary, PSTproducts CHINA Ltd., in Wuxi.
- Site
- Alzenau
- Processes
- EMPT welding (electromagnetic pulse technology), EMPT crimping, EMPT forming (high-speed forming processes), Burr-free cutting (EMPT), EMPT flanging (contactless), EMPT compression of cable strands and powders, Tube compression and tube expansion, EMPT sheet metal welding (lap welding, up to 2 m seam length in a single pulse)
- Materials
- Aluminium, Aluminium 6000 series alloys, Aluminium 7000 series alloys, Aluminium EN AW-6082 T6, Steel, Copper, Copper wire / copper cable strands, Aluminium casting (aluminium die-cast nodes)
- Certificates
- Endurance testing (24/7 over several months)
- Founded
- 2003
- Industries
- Battery production, E-mobility & lightweight construction, Sheet metal applications, Tube applications, Packaging industry, Pharmaceutical packaging technology
- 01
Engineering & prototyping with FEM simulation
- 02
Manufacture of pulse generators and tooling coils
- 03
Assembly of the EMPT machine systems
- 04
Automation & systems engineering
- 05
Endurance testing and quality assurance
- 06
Service and rental (ProPulse)
Materials and Processes
Electromagnetic Pulse Technology (EMPT)
Contactless welding, joining, forming and cutting of electrically conductive metals with a process time of approx. 25 µs without heat input.
EMPT welding / sheet metal welding
Lap welding of flat structural components, with flat welding coils up to 2 m seam length in a single pulse.
EMPT crimping
Joining of tube, cable and hybrid connections, e.g. copper cable lugs onto copper cable strands.
EMPT forming (tube compression/expansion, flanging)
High-speed forming and contactless flanging, e.g. closure caps onto bottle necks.
Burr-free EMPT cutting
Cutting of electrically conductive metals without burr formation.
Multi-joining coils (MJo)
Patented coils that join multiple components simultaneously in a single pulse, frequently used in packaging technology.
Numerical simulation (FEM)
Shortens adaptation and development phases in prototyping and further development of the machine systems.
Sites
Alzenau
DEHeadquarters, development and manufacturing
- Lot size
- Prototype to mass production
- Materials
- Aluminium, steel, copper, aluminium casting
- Pulse generators PSxx-16/25 BlueWave Industrial
- Pulse generators PSxx-16/20 BlueWave Standard
- Pulse generator PS64-16 (64 kJ)
- Tube compression and tube expansion coils
- Flat welding / sheet welding coils (web width 5–15 mm, up to 2 m length)
- Multi-joining coils (MJo)
- Automated systems with robot, rotary table and transfer belt workpiece carriers
Wuxi
CNSubsidiary PSTproducts CHINA Ltd. (since 2022)
Components and Applications
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| EMPT welding (electromagnetic pulse technology)Joining | – | – | – | – | Aluminium, Steel, Copper, Aluminium casting, Cu-Al mixed joints, silver-plated/nickel-plated copper |
| EMPT crimpingJoining | – | – | – | – | Aluminium, Steel, Copper, Al/Cu cables |
| EMPT forming (high-speed forming processes)Forming | – | – | – | – | electrically conductive metals, Aluminium |
| Burr-free cutting (EMPT)Machining | – | – | – | – | electrically conductive metals |
| EMPT flanging (contactless)Forming | – | – | – | – | Aluminium |
| EMPT compression of cable strands and powdersForming | – | – | – | – | Copper, Powders |
| Tube compression and tube expansionForming | – | – | – | – | Aluminium, Steel |
| EMPT sheet metal welding (lap welding, up to 2 m seam length in a single pulse)Joining | – | 2 m (weld seam in a single pulse) | – | – | Aluminium, Aluminium casting, Steel |
| Engineering & prototyping with FEM simulationEngineering | – | – | – | – | – |
| Automation & systems engineering (robot, rotary table and transfer belt solutions)Assembly | – | – | – | – | – |
| EMPT joining of battery components (battery housings, busbars, cell casings, pack clamping)Joining | – | – | – | – | Aluminium, Copper, Al-Cu hybrid |
| Endurance tests / customer-specific product tests for quality assuranceTesting | – | – | – | – | – |
7 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| EMPT machine system (pulse generator + tooling coil) | PSTproducts PSxx-16/25 BlueWave Industrial | – | – | – | Alzenau, Germany |
| EMPT machine system (pulse generator + tooling coil) | PSTproducts PSxx-16/20 BlueWave Standard | – | – | – | Alzenau, Germany |
| Pulse generator PS64-16 (64 kJ system) | PSTproducts PS64-16 | – | – | – | – |
| Tube compression and tube expansion coils | PSTproducts | – | – | – | – |
| Flat welding coils / sheet welding coils (web width 5-15 mm, coil length up to 2 m) | PSTproducts | – | – | – | – |
| Multi-joining coils (MJo coils, patented) | PSTproducts MJo | – | – | – | – |
| Automated EMPT systems with robot, rotary table and transfer belt workpiece carriers | PSTproducts | – | – | – | – |
Additional services
Quality
Endurance tests on generators and coils over several months in 24/7 operation serve the continuous quality assurance of the EMPT systems. Customer-specific product tests and endurance tests complement the prototype phase as part of engineering.
| Evidence | Alzenau |
|---|---|
| Endurance testing (24/7 over several months) |
History
- 2003
Dr. Pablo Pasquale and Dipl.-Vw. Wolfgang Schütz found PSTproducts GmbH and begin the industrial development of EMPT.
- 2004/2006
New development of pulse generators and long-life tools; worldwide first patents for multiple joining.
- 2007
Introduction of the PSxx BlueWave Industrial pulse generator model series; FEM simulation becomes part of prototyping.
- 2008/2009
First representative offices in Sweden, the USA and India; machines running in 24/7 operation.
- 2009/2013
Development and industrialisation of EMPT sheet metal welding.
- 2014/2018
Machine installations in China for battery manufacturing; build-up of automation expertise and offering of turnkey systems.
- 2019
Worldwide expansion in relevant markets.
- 2022
Opening of PSTproducts CHINA Ltd. in Wuxi, Jiangsu province.