Physical
Prototypes and small-series production
Prototype manufacture at ThyssenKrupp Drauz Nothelfer supplies dimensionally and geometrically accurate cut-and-weld circumferences (model manufacture / show-cars), prototype components and assemblies up to complete bodies – quickly and cost-effectively.
Our main focus in this respect is to meet all our customers’ requirements as economically and quickly as possible from one single source. As the interface between development and series production we see ourselves as a motor of innovation in order to identify and exploit synergies from the very start of the process.
With its production intent prototype manufacture, ThyssenKrupp Drauz Nothelfer also provides evidence of reliable forming and joining technology at a quality comparable to that of the series-production.
We are primarily specialising in sheet metal forming of all qualities and geometries, whether for structural components (floor, tunnel, side member, reinforcement A-pillar etc.) or outer panels (doors, bonnets/tailgates, fenders) including major parts such as the roof and bodysides.
Outside the automotive industry too, ThyssenKrupp Drauz Nothelfer is known for the production of small series tooling such as that used for sanitary and commercial vehicles.
Due to commitment, innovation and flexibility, prototype manufacture takes in the wider view facing many new challenges.
Services
- Feasibility study and safeguarding
- Design
- Model manufacture
- Cut-and-weld / prototype manufacture
- Mechanical manufacture
- Press
- Laser
- Body-in-white
- Quality assurance
- Project management
- Workshops regarding component optimisation during the SE phase
- Integrated product and process development
- Administrative customer support service on site
Tooling
- Planning and development of prototype tooling for the manufacture of prototype components as well as manufacture and tryout of tooling in the prototype tooling manufacture
- Variable tooling concepts from pure panel manufacture to safeguarding of the series process
- Tooling materials: cast iron, steel or plastic
- Tooling tryout
- Manufacture of prototype tooling
- Manufacture of prototype tooling with synthetic-resin-bonded grey cast iron
- Manufacture of prototype tooling with production intent to safeguard the series process in co-operation with the SE team
- Manufacture of small-series tooling
Fixtures (assembly)
- Simple fixtures only for assembly and fixtures for process safeguarding
- Conventional prototype fixtures
- Prototype fixtures with production intent
- Variable solutions for different project requirements by means of a consistent modular system in the design of equipment
Single panels / assembly
- Press shop with large hydraulic presses of 400-2,000 t
- Single panels of steel (high-strength, tailored blanks), stainless steel, aluminium
- Manufacture of body components through to complete bodies
- Use of all relevant joining processes such as spot-welding, MIG-welding, laser welding and brazing, Tox clinching, riveting, gluing, clinching (3D 5-axis laser systems, rough and final trim, laser welding (offline programming)
- Side-lock seam jointing
- Robotic hemming
- Eckold hemming
Welding groups / special purpose vehicles / assembly
- Assemblies up to complete bodies
- Installation, assembly, complete vehicle build-up "Body in White” / special purpose vehicles / functional trials incl. paint and KTL (extended workbench at OEM level)