Development, toolmaking and prototype to small-series production of complex sheet metal parts and assemblies
TECHNIK in FORM Blechbearbeitung GmbH
Heilbad HeiligenstadtNew on Amplifa
Expertise in Sheet Metal Processing and Forming Technology
TECHNIK in FORM Blechbearbeitung GmbH, based in Heilbad Heiligenstadt, is a development and manufacturing partner for complex sheet metal parts, formed parts and assemblies. The company supports customers from the initial idea through design, forming simulation and in-house toolmaking all the way to the finished, ready-to-install assembly. The focus is on prototypes, individual parts and small series of up to 10,000 parts per year. Manufacturing capabilities include deep drawing, embossing and edge bending with presses up to 1,200 t (12,000 kN), 2D and 5-axis laser cutting and welding, as well as welding robots and spot welding. Materials processed include steel, ultra-high-strength sheet, stainless steel, aluminium, titanium as well as tailored blanks, sandwich and dimpled sheet. Customers come from the automotive industry, rail vehicle construction, medical and device technology, aerospace, energy, robotics and mechanical and plant engineering. Together with its sister company DESIGN in FORM Fertigungstechnik GmbH, the company founded in 1994 offers a high degree of in-house manufacturing depth on 2,015 m² of production space.
- Site
- Heilbad Heiligenstadt
- Processes
- 3-axis laser beam cutting, 5-axis laser beam cutting, 5-axis laser beam welding, Edge bending/edging, Embossing, Deep drawing, Special parts production (threaded inserts, tubes, pipes, wires), Manual production (straightening and deburring work, manual sample production, tool finishing)
- Materials
- Steel, Stainless steel, Aluminium, Titanium, Ultra-high-strength sheet, Tailored blanks, Sandwich sheet, Dimpled sheet
- Certificates
- DIN EN ISO 9001:2015, DIN EN ISO 3834-2:2021, DIN 2303 Q2, EN 15085-2 (welding of rail vehicles), TISAX, EMAS, TOTAL E-QUALITY distinction, ISO 14001 (2009, later converted to EMAS), EN 15085-2, DIN EN ISO 3834-2
- Founded
- 1994
- Industries
- Automotive industry and suppliers, Rail vehicles/rail industry, Medical and device technology, Aerospace, Energy, Robotics and automation technology
- 01
Development & Design (CAD, CATIA, NX, Rhino, forming simulation Stampack)
- 02
Toolmaking (forming and stamping tools, prototype tools)
- 03
Laser processing (2D/3D/5-axis cutting and welding)
- 04
Forming technology (deep drawing, embossing, edge bending, special parts)
- 05
Welding and spot welding (welding robots)
- 06
Assembly manufacturing and assembly
- 07
Quality assurance (3D CNC metrology, inspection plans)
Materials and Processes
Steel
Base material for formed, laser-cut and welded parts, including ultra-high-strength sheet for lightweight construction.
Ultra-High-Strength Sheet
For lightweight construction, processable by deep drawing and embossing processes.
Tailored Blanks
Plated sheet blanks for forming-related prototype and small-series parts.
Sandwich Sheet
Lightweight material for formed parts with requirements for weight and stiffness.
Stainless Steel
Processing in laser and welding applications, among others up to 6 mm on the 2D flatbed laser.
Aluminium
Laser-processable up to 5 mm and relevant for lightweight construction applications in aerospace.
Titanium
Processed for demanding assemblies, particularly in aerospace.
Laser Processing (2D/3D/5-Axis)
Flexible trimming tool for prototypes, with working areas up to 4,000 x 2,000 x 600 mm.
Toolmaking
In-house manufacturing of forming, stamping and prototype tools, active inserts and fixtures.
3D CNC Metrology
Horizontal arm and gantry measuring machines with tactile scanning systems for geometry and free-form surface measurements.
Locations
Heilbad Heiligenstadt
DEProduction and Administration
- Lot size
- Quantity 1 to 10,000 parts/year
- Materials
- Steel, stainless steel, aluminium, titanium, tailored blanks, sandwich and dimpled sheet, castings, plastics
- Press 500 t
- Press 300 t
- Press 1,200 t (2 units)
- 2D flatbed laser 2,700 W (1,600 x 3,000 mm)
- 3D flatbed laser 5,000 W, 5-axis (4,000 x 2,000 x 600 mm)
- 3D laser cutting and welding system
- Spot welding and welding robots
- Synchronized 2-robot welding machine
- 3-axis machining center (2,200 x 1,750 x 750 mm)
- 5-axis machining center (4,200 x 2,050 x 1,100 mm)
- CNC turning machining center (Ø 300 x 700 mm)
- NC surface grinding machine
- CNC press brake
- 3D horizontal arm measuring machines (Renishaw)
- 3D gantry measuring machine (Tesa)
- Handling robots for automated assembly
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| 3-axis laser beam cuttingForming | – | 3000 mm × 1600 mm | – | Quantity 1 – 10,000 parts per year | Steel, Aluminium, Stainless steel |
| 5-axis laser beam cuttingForming | – | 4000 mm × 2000 mm × 600 mm | – | Quantity 1 – 10,000 parts per year | Steel, Aluminium, Stainless steel |
| 5-axis laser beam weldingJoining | – | – | – | Quantity 1 – 10,000 parts per year | Aluminium, Steel, Stainless steel |
| Edge bending/edgingForming | – | – | – | Quantity 1 – 10,000 parts per year | Steel, Non-ferrous metals |
| EmbossingForming | – | – | – | Quantity 1 – 10,000 parts per year | Steel, ultra-high-strength sheet, tailored blanks, stainless steels, sandwich sheet |
| Deep drawingForming | – | 2450 mm (max. tool dimensions) × 1600 mm (max. tool dimensions) | – | Quantity 1 – 10,000 parts per year | Steel, ultra-high-strength sheet, tailored blanks, stainless steels, sandwich sheet |
| Special parts production (threaded inserts, tubes, pipes, wires)Forming | – | – | – | – | Steel, Non-ferrous metals |
| Manual production (straightening and deburring work, manual sample production, tool finishing)Forming | – | – | – | – | – |
| Milling of workpieces (castings, steel, plastics) up to 6 t raw part weightMachining | – | – | 6 t | – | Castings, Steel, Plastics |
| High-speed and hard machiningMachining | – | – | – | – | Steel |
| 5-axis simultaneous machining for complex deep drawing toolsMachining | – | – | 6 t | – | Steel, Castings, Plastics |
| Toolmaking (forming and stamping tools, active inserts, joining fixtures, measuring fixtures)Toolmaking | – | – | – | – | Plastics, Steels |
| Engineering | – | – | – | – | – |
| Assembly manufacturing (with fixtures and inspection procedures)Assembly | – | – | – | Quantity 1 – 10,000 parts per year | Steel, Stainless steel, Aluminium, Titanium |
| Quality assurance (3D CNC metrology, free-form surface and geometry measurements, reengineering)Testing | – | 3500 mm × 1500 mm × 1600 mm | – | – | – |
| Welding (welding robots, welded joints)Joining | – | – | – | – | Steel, Stainless steel, Aluminium |
19 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| 3-axis machining center | – | – | 2200 x 1750 x 750 mm | – | Heilbad Heiligenstadt |
| 5-axis machining center | – | – | 4200 x 2050 x 1100 mm | – | Heilbad Heiligenstadt |
| CNC turning machining center | – | – | Ø 300 x 700 mm | – | Heilbad Heiligenstadt |
| NC surface grinding machine | – | – | 600 x 400 x 375 mm | – | Heilbad Heiligenstadt |
| 2D flatbed laser | – | – | 1600 x 3000 mm | – | Heilbad Heiligenstadt |
| 3D flatbed laser (5-axis, swiveled) | – | – | 4000 x 2000 x 600 mm (swiveled 3500 x 1500 x 600 mm) | – | Heilbad Heiligenstadt |
| Press 500 t | – | 1 | – | 1998/99 | Heilbad Heiligenstadt |
| Press 300 t | – | 1 | – | 2004 | Heilbad Heiligenstadt |
| Press 1,200 t | – | 2 | – | 2004, 2018 | Heilbad Heiligenstadt |
| 3-axis laser cutting system | – | 1 | – | 2001 | Heilbad Heiligenstadt |
| 2D laser cutting system | – | 1 | – | 2009 | Heilbad Heiligenstadt |
| 3D laser cutting and welding system | – | – | – | 2018 | Heilbad Heiligenstadt |
| Spot welding machine | – | – | – | 2000 | Heilbad Heiligenstadt |
| Welding robot | – | – | – | 2009-2022 | Heilbad Heiligenstadt |
| CNC measuring machine | – | – | – | 1995, 2004 | Heilbad Heiligenstadt |
| manually guided 3D horizontal arm measuring machine (Renishaw) | – | – | 2370 x 800 x 800 mm | – | Heilbad Heiligenstadt |
| CNC-controlled 3D horizontal arm measuring machine (Renishaw) | – | – | 3500 x 1400 x 1600 mm | – | Heilbad Heiligenstadt |
| CNC-controlled 3D gantry measuring machine (Tesa) | – | – | 900 x 1500 x 800 mm | – | Heilbad Heiligenstadt |
| Handling robot | – | – | – | 2025 | Heilbad Heiligenstadt |
Additional services
Quality and Certifications
Quality assurance is carried out with 3D CNC measuring machines (horizontal arm and gantry measuring machines from Renishaw and Tesa) including an optical line laser sensor and PC-DMIS software. The management system is certified according to DIN EN ISO 9001:2015 and is monitored through internal and external audits.
| Evidence | Heilbad Heiligenstadt |
|---|---|
| DIN EN ISO 9001:2015 | |
| EMAS | |
| TISAX | |
| EN 15085-2 | |
| DIN EN ISO 3834-2 | |
| DIN 2303 Q2 |
Company History
- 1994
Founded by the brothers Ulrich and Hubert Biehler, start of production in a rented hall
- 1995
Own design department, first CNC milling machine and CNC measuring machine, start of apprenticeship training
- 1996
Own toolmaking, start of deep drawing production, first CAD workstation
- 1997
Purchase of the property, founding of the sister company DESIGN in FORM Fertigungstechnik GmbH
- 1998/99
First production hall with 600 m², first 500 t press, initial certification according to DIN EN ISO 9001
- 2000
Expansion of production space to 1,000 m², first spot welding machine
- 2001
First 3D laser cutting system, start of 5-axis laser processing
- 2004
Office building and warehouse, internationalization of the business, 300 t and 1,200 t presses, new CNC measuring machine
- 2009
Expansion to 1,540 m² of production space, 2D laser cutting system, first welding robot
- 2010
Establishment of a milling center for apprenticeship training
- 2013
Second welding robot, new measuring room with inspection station for welded joints
- 2015
Initial certification of environmental management according to ISO 14001
- 2016/17
Expansion to 2,015 m² of production space, new CNC press brake
- 2018
New 1,200 t press, 3D laser cutting and welding system, ISO 9001:2015, EMAS, EN 15085
- 2019
Additional spot welding robot
- 2020
TISAX certification
- 2022
Synchronized 2-robot welding machine
- 2023
Switch to a new ERP/PPS system
- 2025
Certification according to DIN 2303 Q2, handling robots for automated assembly