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GERGM&F Services

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Services
Move the mouse over the graph to discover the service areas.
Individual Production
We materialise ideas.

With our comprehensive expertise in combination with the enormous production depth we realise almost every project – from the first scratch to the final touch.

Engineering
Quality Assurance
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we materialise

...if it has to be good

Unique infrastructures combined with specialised development competence enable us to implement projects of greatest complexity. In the process we deploy our network of strong partners embedded directly in one of our development centres.
Individual Production
We materialise ideas.

With our comprehensive expertise in combination with the enormous production depth we realise almost every project – from the first scratch to the final touch.

Engineering
Quality Assurance


  • Fräsen


Engineering

Construction

Construction

In line with your demand, our engineers develop solutions with the perfect material, appropriate for use and economical: from cubing models and test equipment, casting technology for modelling, model making technology or jigmaking as far as complex tool constructions.

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We design components as well as the required tools with state-of-the-art programs. Our highly skilled specialists have a broad wealth of experience in the fields of model making, automotive and mechanical engineering. Amongst others, our design department is excellently acquainted with:

  • the development of multipart silicone and PU- casting and injection tools
  • cubings and test cubings (interior, exterior) including design concepts made of plastics, aluminium or steel
  • all kind of welding structures
  • comprehensive solutions for the manufacture of special purpose machinery
  • complete prototypes for the automotive industry, for aviation, aerospace and medical engineering

We read and process the following data: Catia V5, Pro/Engineer, FiberSim, TEBIS, AutoCAD, Alias, IGES, VDA und STEP, DXF, DWG

Infrastructure:
Catia V5
Pro/Engineer
Solid Works
FiberSim
TEBIS
AutoCAD
Solid CAM
Cimatron
Peps 3D
Systems for STL
Power Inspect
Alias

Interfaces:
Mastercam
IGES
VDASTEP
DXF
DWG
Parasolid
Solidworks
VX
Z3
CATIA
PRO/E
UNIGRAPHICS
and many more.

 

 
 


Development

Development

We develop and calculate structural mechanics and fluid dynamics in close cooperation with our partner KLK Motorsport. Thanks to our short on-site ways, construction, calculation and production are tightly intertwined.

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Our long-lasting partnership with KLK allows us to keep the process chain in-house, thus minimising interface problems and conflicts of interests. A comprehensive and single-source solution is to your benefit providing you with a high adherence to schedule as well as budget reliability. We guarantee absolute secrecy and provide data security via Odette file transfer protocols, amongst others.

 
 


Process & assembly engineering

Process & assembly engineering

Pursuing new solutions for products or manufacturing steps is part of our internal development. With our engineering and science driven approach we guide our clients all the way from the idea to a safe production process.

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Process and production engineering contains development, optimisation and the organisation of workshop and machine procedures.
With our production possibilities, we can realise the optimum solutions.

Innovative ideas or extraordinary component requirements sometimes seem to cause irresolvable problems to the production process. With our innovation dynamics we have managed to institutionalise the process and production engineering over the years. On this basis, we are continuously enhancing our processes. The manufacturing of components or the production management seems irresolvable? We are your competent partner to find the right solution and efficiently implement all your requirements.

Our procuction and process management is neither tied to a particular sector or internal infrastructure, nor is it dependent on specific material or processing. That means we offer our services to all sectors with challenging assembly tasks, no matter what kind of processing material is required and in any stage of development.

Due to our wide-ranging competence concerning materials, applications and engineering services as well as our great depth of production and our extensive network, we are able to offer you manufacturing expertise on the highest level, starting from the design up to series production.

Examples:

  • Problem: A sandwich panel (CFK/aluminium) for a satellite housing cannot be manufactured. Solution: GERG develops the manufacturing.
  • Problem: Serva Transport Systems –prototypes exist, however, without performance specifications and required improvement regarding product performance and production. Solution: GERG develops a series concept and its production.
 
 


 


Individual Production

Prototypes – Idea in, Product out

Prototypes – Idea in, Product out

We design, plan, develop, design, manufacture; we finish, assemble and document prototypes as test-, function- or illustration models. Thanks to our enormous in-house production depth, our prototyping is fast, flexible and efficient.

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From the first draft to the final product, a prototype is the benchmark on track. It might equal the target product physically or technically – depending on which parameter e.g. customer response, functionality or technical feasibility is to be tested.

Our long-time experience in the construction of prototypes enables us to implement every step in the process in-house, starting from the idea and going all the way to an individual item ready for serial production. For any kind of requirement we are flexible to choose the right material and the most effective application in order to manufacture a high-end quality product fast and efficiently. That is how we create valuable synergy effects. Every application and every process step is accompanied by the specific specialists and the corresponding infrastructure: from the designer’s first draft, towards project management, to the final control of the class A surfaces.

The combination of engineering know-how, handcraft and the comprehensive manufacturing and process technology distinguish us as a powerful single-source supplier for the industry and technical enthusiasts.


Projekte

 
 


Small-series production

Small-series production

From the first line to the final touch: we offer exclusive small-series of high-end vehicles as well as the efficient production of components. We combine the best of both worlds, we are a manufactory or a systems supplier – it is your choice.

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We are well-prepared for the individual production in small quantities. Machinery with short changeover and retooling times or automatic assembly allow cost-effective small-series production with highest process reliability. Bar loader-aided turning and palette exchanger-aided milling facilitate serial machining. Casting technologies are generally serial production applications with the major part of cost being generated by the tool making. Hence, cost per unit decline significantly in relation to the batch size. Depending on the component size, various casting machines for different tool sizes are available. Also, the quality control via NC measurement is adjusted to small-series production. Defined checkpoints are processed automatically. Finally, our storage management permits tracking the used materials per batch.

Besides the cost-driven tasks, the company Modell- und Formenbau Blasius Gerg GmbH has always been a handcraft business. Since the founding of the company we always have been living the manufactory idea with passion. We provide individual items and small series of highest quality and with a production depth unrivalled in this field.

 
 


 
 


Precision Manufacturing

CNC milling

CNC milling

Our experienced specialists implement intelligent milling strategies on state-of-the-art machinery. From the delicate precision engineering component to the adaption of complete vehicles, from plastics to titanium, from simple to highly complex work – the result always represents maximum precision.

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We are able to create complex geometry in plastics, composites, aluminium, MMC and also in very hard-to-machine materials such as titanium or high-strength steels for applications in aeronautics. Short processing times are guaranteed due to the simultaneous machining of five sides and the use of palette exchangers.

Our machinery in operation is state-of-the-art and features an enormous base accuracy. The latter is ensured by special groundings, high geometry standards in the set-up and climatisation of the production halls.

Extensive raw materials in stock, diverse machinery and short ways within the individual departments reduce the lead time and allow parallel production processes. Close quality control allows efficient check measurements in line with the production process.

For more than 20 years we cooperate with Tebis AG in a development partnership and work with our own postprocessors. Our highly experienced and skilled specialists evolve sophisticated milling strategies as these bear high potential regarding feasibility and cost. In order to ensure improvement we implement milling tests on a regular basis.

One of our specialities in the milling department is the machining of MMC, a particularly tough silicious aluminium alloy used in motorsports, and the machining of titanium with specifically designed machinery.

Unique in this sector is our capacity to offer the complete process chain from CAM to CAD, milling, lining, finishing and quality assurance from a single source.

Infrastructure:

  • 32 ultra-modern milling machines with up to 6 axes

Special features:

  • Travel up to 8,000 x 4,000 x 2,750 mm
  • Specifically designed machinery for processing titanium and aviation steels
  • Specialisation in components with high demands on geometric tolerances
  • Processing of all metals, plastics as well as fibre-reinforced construction materials
  • Single-source up- and downstream process steps
  • Hard to source, hardened and tempered materials in stock
  • Thin-walled components

Application examples:

  • Machining of welded frames
  • Titanium add-on parts for motorsports and aviation
  • Customised production (3D-data or 2D-drawings)

 

Image: in-house development for high-precision machining of huge materials and materials with difficult machining characteristics

 
 


Turning

Turning

From a simple turned part to a highly complex turning / milling component, as an individual item or for series – we always meet our customers’ demand. With different machinery types and sizes we reduce the processing time whilst increasing the quality of the workpieces.

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The clever combination of turning and milling with other manufacturing technologies, e.g. eroding, curbs our production costs and boosts the manageable complexity of the components.

We process all metals and plastics as well as fibre-reinforced materials. Our core competence is the precise machining of high-strength materials. Therefore we have created our own machinery park containing particularly stiff and low-vibration equipment. Our specialists with decade-long experience develop strategies which make the crucial difference when it comes to tight geometry or critical raw materials such as titanium. Another characteristic is that every machine operator is at the same time the programmer of the corresponding workpiece. Hence, another interface is skipped for the benefit of reliability and quality.

We achieve the maximum of accuracy through air-conditioned production halls, high-quality tools and process-related quality checking with dimensional measurement systems such as roughness testers and profilometers. In case of urgent orders our clients benefit from our excellently equipped inventory containing even high-strength steels for aeronautic applications which often are only available with considerable difficulties.

Infrastructure:

  • 10 state-of-the-art NC turning machines plus turn-mill centres
  • Basic milling machinery, partly equipped with bar loaders, as well as huge turning and milling centres with a high degree of machining depth

Application examples:

  • Prototypes of light-alloy wheels for cars
  • Titanium parts for aviation
  • Production according to customer requirements (3D-data or 2D-drawings)
  • Components for motorsports and aeronautical applications

 

Reference projects:

  • Wheel nuts
  • Oil tanks
  • Ball

 
 


Selective laser melting (SLM)

Selective laser melting (SLM)

Selective laser melting allows flexible yet economical manufacturing of high-strength components while offering maximum freedom of design. Together with our other manufacturing technologies selective laser melting releases its potential.

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Selective Laser Melting (SLM) is an additive manufacturing process often referred to as 3D printing. Currently we can fabricate parts up to a volume of 240x240x280 mm, that cannot be realised through classic manufacturing processes. In the process SLM layer by layer with a thickness from 25 to 60 µm is melted by a 400W diode laser and is solidied close to contour. We process aluminium (AlSi10Mg), high-strenth tooling steel (1.2709) and titanium (Ti6Al4V).
The almost complete freedom of design allows the production of highly optimised load-specific components. It´s economically remarkable that production costs do not depend on part complexity.

 

In combination with our other manufacturing technologies, we offer customized solutions. Examples given:

  • Complex SLM-part are post processed on high-precision milling- and turning machines, assembled to bigger components and finished for delivery.
  • A SLM-part in bionic design is integrated in a CFRP structure. The result is a high performance hybrid structure
  • The whole value-creation chain: description and definition of the component >> design >> topological optimisation >> FE simulation >> design adaptations >> manufacturing by SLM technology >> post processes (milling, welding, bonding, surface treatment …) >> quality assurance

 
 


Welding

Welding

We work with almost every weldable material. No matter if WIG manual welding or precision laser welding: the welds we produce are particularly lean and process reliable and the thermal distortion of the workpiece is marginal.

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A speciality of our in-house laser welding technique is the possibility to incorporate filler in order to stabilise structures. Almost all fusion-weldable materials are suitable for this application. The WIG welding technique with its wide range of usable raw materials, the good accessibility and the perfect weld pool control makes an ideal complement to laser welding. This combination allows us to build complex high-performance modules with up to 2 m3, for example attachable frames or supsension components for motorsport.

For example, we create welding constructions out of high-strength steel (1.7734), aluminium (EN AW-6082) or titanium (Ti6Al4V). Amongst others we also build complex hollow structures consisting of many single sheets (tmax = 3mm). High process reliability and repeat accuracy with minimal thermal distortion are crucial when it comes to the reliable realisation of components with extremely high mechanical load capacity.

Our know-how allows us to join aluminium sheets (6000) susceptible to solidification cracking. We generate mechanical strength properties within the weld and the heat affected zone of up to 75-80% of the base material for the alloy EN AW-6082; completely without subsequent thermal treatment.

Infrastructure:

  • Laser welding system for component dimensions of approx. 600 x 600 x 500mm
  • WIG welding system Rehm Invertig PRO digital 350 AC/DC
  • Demmler welding table 1000 x 2000mm
  • Welding table / measuring table 1500 x 2500 mm

 
 


Wire-cut EDM – precision under power

Wire-cut EDM – precision under power

Eroding is the method by which we process all conductive materials true to size and geometrics – independent of their hardness. We are able to produce minimal cut widths and sharp-edged outlines with a spectacular accuracy of only a few thousandths of a millimetre.

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With wire EDM, a wire cuts through a workpiece. Due to an electric process, material is released from the workpiece close to the wire. This allows a very high degree of accuracy with the omission of cutting pressure and a cutting volume at molecular scales.

The wire has a thickness of 0.25 mm and is CNC-control guided through the component part. This procedure requires a lot of experience – therefore we have appropriate specialists. The combination of in-house turning, milling and welding techniques together with the eroding technology enables us to offer you a comprehensive treatment of all metallic materials.

Infrastructure:

  • 1 CHARMILLES Robofil 440cc (Verfahrwege im mm: X 550, Y 350, Z 400)
  • 1 CHARMILLES Robofil 220cc (Verfahrwege im mm: X 350, Y 220, Z 220)

Application examples:

  • Internal gearing (continuous)
  • distortion-free, hardened small components made of block material (efficient)
  • Custom-fit finishing with repeat accuracy, e.g. slots, notches, square-cut parts



Special features:

  • Close connection to process steps of model making and engineering
  • Equipment is crafted individually (with free formed surfaces)
  • Complex components from a single source



Reference objects:

  • Splines
  • Universal integrated tooth gearing (RARB, FARB TR, Driveshaft TMG)
  • Crank
 
 


Laser marking

Laser marking

We have two laser engraving systems on our site, with which we can quick and permanently designate components or labels with different surface materials like CFK, steel, titanium, aluminium, PEEK, POM, PVC or varnish.

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Infrastructure:

  • FOBA G5
  • ACSYS Piranha
 
 


Assembly

 We set up components and modules reliably using diverse joining techniques such as welding, screwing, riveting or adhesive bonding. Further we deploy inserts and bushings and finally conduct adaption- and adjustment steps.

 

 



 


Composites – Efficiency Down to the very Last Fibre

Our combined know-how in the fields of infusion, core and braiding technology is unique. We thoroughly align individual materials and process steps. The outcome is lightweight construction, which demands maximum capacity of the materials in use.



Prepreg autoclave technology

Prepreg autoclave technology

From the autoclave directly on the circuit: Based on our extensive professional expertise and long-time experience we are able to produce anything starting from simple cladding components up to highly complex gear box housings or complete monocoques of world class quality.

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Fibre mats impregnated with resin are used in the prepreg treatment. In the autoclave these workpieces are then cured at high temperatures and under pressure. The resulting components are extremely high-performing due to the high fibre volume content.

Depending on demand and intended purpose we chose the adequate technology: Sandwich constructions, the integration of inserts, different lost core or blown core technologies in order to generate hollow bodies and undercuts.

Our expertise in the area of prepreg technology with all its upstream and downstream processes is broad and profound. In combination with our excellent infrastructure, especially for motorsports applications, we are your powerful provider for complete assembly groups.

Infrastructure:
We work with autoclaves with up to 4000 mm usable inside length and a diameter of 2200 mm (400°/20 bar).

 
 


Low-pressure RTM

With our RTM (Resin-Transfer-Moulding) process we generate series quality. As the resin is injected in the low-pressure range it is possible to work with more economic tooling. Also the curing at room temperature or in heated tools reduces costs. This method is especially suitable for prototyping.



VPL (vacuum press lamination) – vacuum infusion method

VPL (vacuum press lamination) – vacuum infusion method

We have developed our unique processing technology for CFRP components with all-sides mouldface surfaces. VPL parts are furnished with special features, which you will only find with us.

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VPL is an enhanced version of the CFRP injection technique (RTM) using lost cores. That is how we reach a level of geometric freedom, which was formerly only possible via casting or rapid prototyping technology. VPL is applicable for parts with complex contours or undercuts. The surface quality of our VPL laminates is particularly sophisticated, usable up to temperatures of 220 degree Celsius. Of course they retain their extraordinary accuracy and properties. Possible component sizes start at 1 g and go to a maximum volume of 1,200 x 800 x 800 mm. Moreover, compared to other composite processing techniques, complex pieces can be manufactured within shorter periods.

The leading competitors of endurance racing in the past years, for example, are equipped with our ultra-light air boxes in VPL design.

Application examples:

  • Air boxes with flow channels
  • Tubes, channels and containers for oil, air or water
  • Hydraulic components
  • Bell and gear boxes housings with inserts

 

Infrastructure:
Custom-developed technology for internal and external mould face surfaces

 
 


Braiding facility with robot-aided core feeding

Braiding facility with robot-aided core feeding

Our braiding machine automatically generates near-net-shape textile fabrics. Clear advantages compared with traditional handcraft are cost efficiency and the exact reproducibility.

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One of two available braiding machines in Germany with 144 carriers is located at our site. This machine enables us to produce customised hollow components and C-profiles made from CFRP. The robot-aided core feeding system allows reproducible braiding around curved and concave structures with filler threads on the inside and outside surface. The machine allows modification for different circumferences starting from 100 mm as the number of threads is variable. Due to large-sized centre opening we are able to braid structures with a length of up to 7 m. On demand it is possible to produce a variety of cross-sectional geometries and surfaces over the entire length of a component.

Our main technologies include blow - and foam cores which in combination with the braiding create synergy effects. Being our client you particularly benefit from compatible single components and short delivery times.

The horizontal braiding machine has 144 carriers and an adjustable thread tension. The application of the filler avoids unwanted distortions. The core feeding process is robot-aided.

Application examples:

  • vehicle frames: main frame or traverse, roof column as hollow profiles with integrated inserts
  • frames for aircraft
  • profiles for architectural applications
 
 


Wet lamination (GRP+CFRP)

Wet lamination (GRP+CFRP)

According to your specifications, we supply wet laminated bodywork components as well as inner linings in various material designs and in showcar quality as well as sandwich components with different cores and moulds.

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Due to the major part of manual steps in wet lamination processes, it is especially important to provide an in-depth quality controlling by skilled and regularly trained staff. Production of wet laminated components can be supplied in GRP, CFRP or AFRP depending on their purpose of use. For enhanced laminate quality all parts also can be produced by using vacuum technology. The curing process for huge workpieces takes place in a dedicated tempering hall with a maximum temperature of up to 90 degrees Celsius. Small components are cured in furnaces up to a maximum of 250 degrees Celsius.

Application examples:

  • Showcar components
  • Data control models for serial production
  • Serial tools for the aviation industry

 

Reference projects:

  • Showcar Rolls-Royce 100EX (bodywork and various interior parts)
  • Showcar Mini Clubman (bodywork and various interior parts)
  • Various components for the Russo-Baltique Expression

 
 


 


Modelling & Moulding

Design model making

Design model making

In the supreme discipline of design modelling - the showcar - we present all our skills and capacities. We have the appropriate manufacturing technology for every single detail. Our professional team incorporates the individual components with circumspection and a sharp eye on all essentials.

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Our employees handle all kinds of materials and, besides special attention for the details, always have the big picture in mind. The passion of our model making team is reflected in exact slit and panel alignement as well as the clean cut lines.

The perfect synergy of ultra-modern machines and manual know-how is what creates inspiring design models which fuel enthusiasm.

Infrastructure:
Separate design studio on an area of 235 m²

Special feature:
Stripe light for ideal illumination and processing

Application examples:
Sharker, Russo Baltique

 
 


Surface technology

With state-of-the-art technologies and materials we varnish workpieces up to the size of a car. Our experienced experts perform different surface treatments like sandblasting, special effect paintings or class A quality finish.








Data control models

Data control models

We have developed data control models which are perfect tools for supervising and checking the progress status of components regarding visual effects and feasibility.

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In the development phase, CAD data in the data control model is presented at a reality scale of 1:1 for the very first time. This is an important step toward series maturity as it makes the designer´s and engineer´s work visible. Subsequent modifications can be implemented via reverse engineering in the original CAD model.

Years of experience, our high quality awareness and the high flexibility of our staff stand for excellent data control models. Our expertise in upstream and downstream processes guarantees economic advantages.

 

 

 

 
 


Cubing technology

Cubing technology

We are system supplier of cubing construction components of highest precision – from the smallest control element to the complete body shell framework. Our series monitoring and other testing instruments ensure process reliability in all stages of development.

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The cubing simulates the target state of a component of a body shell framework and is used as a reference model in order to test all connected serial components. As all built-in units are adjusted to a zero measurement, a precise fault analysis in all phases of development is possible.

All original interior and exterior vehicle parts are tested in terms of fit and function with cubing technology. Cubing allows to prove the function of flaps, doors, illumination or gaskets in an early stage. Depending on the intended application, we laminate or cast the testing equipment or we mill it from aluminium. If needed, also other manufacturing techniques can be deployed. Our cubings are set up in a climatised room on a measuring slab to guarantee maximum accuracy.

Infrastructure: Measuring slab with a measurement range of 11000 x 2800 x 2600 mm

 
 


Gauge building

Gauge building

Quality control is vital in order to meet the high requirements that components in the automotive and aviation industry have to fulfil. We produce customised assembly jigs and gauges made from aluminium, steel and fibre-reinforced composites.

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The aim of gauge building is to precisely image and control every component and thus enable the possibility of solid evaluation, documentation and visualisation methods. For every process step up to the smallest detail we produce gauges. Therefore we cooperate closely with our partners from the automotive and aviation industry. Like this the testing equipment we provide is at the highest possible precision level which is required for maximum process safety.

Application examples:

  • Interior components (dash board, roof liners, etc.)
  • Bodywork parts (window aperture, wings etc.)

 
 


Rapid prototyping

Rapid prototyping

We transform your ideas or CAD data directly into show components or workpieces made of metal or plastics. We manufacture transparent, high-strength, rubber elastic or also light-guiding materials in diverse optics as well as complete prototype luminaires in high-end quality.

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With the latest innovative polyjet printing systems we are able to generate finest geometrics and surfaces. Via stereolithography we produce generative parts with photopolymersiation resins. With this we can realise even complex geometrics such as undercuts and hollows. By means of selective laser sintering we generatively process not only plastics but also metal and ceramic materials. Thus, basic material in powder form is converted into workpieces which cannot be produced in conventional mechanical processes. We finish almost all 3D surfaces with diverse textures by using water transfer printing.

For machining we use our precise high speed milling machines. This allows us to realise also small and very elaborate components with highest finishing quality and accuracy.

Among others, luminaire and light technology is our speciality. We provide highly precise first samples and prototypes and also small series. Being the illumination technology of the future, fibre optics are for example used in vehicle construction, interior design or as design applications.

The direct connection to our in-house range of services generates synergy effects of all kinds; from design to construction and programming to the casting of the component in aluminium out of the rapid prototyping mould without further tooling costs.

 
 


PU small series production

PU small series production

PU-casting – all of a piece
No matter if for prototypes or small series from the development phase towards construction until assembly, as a duplicate of your 3D print or the realisation of your 2D plans, whether being a PU (in different types of shore hardness), silicone or fibre-reinforced cast – we supply highly specified castings.

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Our expertise is ground-breaking and outperforms the industry standards by far. We design our own machinery and develop new techniques. We deliver single-, two- and three-component parts in all types of shore hardness. If demanded, castings are reinforced with metal of CFRP. Our portfolio also comprises glass-rubber composites for example glazing with injected sealing. With our know-how we design components more effective or even spare out components, as one part takes over the function of multiple others. All-of-a-piece-like.

Infrastructure:

  • 2 polyurethane high-pressure systems
  • 3 vacuum chambers (max. 2200 x 1300 x 1700 mm)
  • Machinery in-house developed

Application examples:

  • Headlamp housings
  • Air baffles and air ducts; casting of gaskets on CFRP and plastic components
  • Dash board
  • Overmold of window glazing
 
 


Aluminium precision casting (low pressure vacuum casting)

Aluminium precision casting (low pressure vacuum casting)

With the in-house developed precision casting technique we produce parts with minimal wall-thickness, high dimensional accuracy and outstanding surface quality. At Modell- und Formenbau Blasius Gerg GmbH, we offer the complete shape-taking process of the casting package under one roof.

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Low pressure vacuum casting means almost unlimited scope for design. It realises components that are not producible with other methods or if so, only with great efforts. In combination with rapid prototyping, functional parts are generated within a short time.

We realise components within a weight range of grams up to 5 kg for a single unit and with a maximum edge length of 600 mm. We process all castable aluminium alloys. The conditions similar to die casting make our production procedure predestined for serial development or pre-series production. Our system works with a steered moulding process, guaranteeing constant quality. As the moulds are not hot but cold, the resulting part is of finer grain structure. Subsequent heat treatment provides defined mechanical strength properties. With a design optimized for precision casting we can produce weight critical parts with a minimal wall thickness of 0.8 mm.

Another great advantage of our precision casting technique is its flexibility. On the one hand we reach excellent quality regarding size accuracy and surfaces by milled models; on the other hand we optionally integrate 3D printing components for small units without much additional tooling costs. This method is not only useful for prototypes or initial samples but also for small and medium-sized batches up to 500 units.

Application examples:

  • Pump parts
  • Interior components
  • Induction pipes

 
 


 


Quality Assurance

Geometric testing

Geometric testing

Besides know-how and experience, our measurement and testing methods are uncompromising and assure all demanded quality standards. No matter if measurement via technical drawing or CAD data, our comprehensive quality management is provided in-house.

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For the setup of complete vehicles or similar structures we have duplex measuring machinery in different sizes and a CNC portal coordinate measuring machine at ground level. All equipment is operated by skilled staff with the relevant methodological know-how. A Faro arm is available for measuring mobile applications or angled objects such as vehicle interiors. It is additionally equipped with a 3D scanner to measure surfaces efficiently. Not-easy-to-access sections we are able to check by means of endoscopy; surfaces we can examine with an optical microscope equipped with a camera system.

Application examples:

  • Set up of test cubing as leaders
  • Complete quality assurance after design and production of various testing equipment parts

Infrastructure

  • Ground level duplex measuring machines up to 11,000 x 3,100 x 2,400 mm
  • CNC portal coordinate measuring machine up to 2,500 x 1,000 x 2,000 mm
  • Optical measuring microscope with camera system
  • Measurement precision at 1µm

 
 


Non-destructive material testing – thoroughly put to test

Our portfolio comprises various non-destructive testing methods, e.g. magnetic particle and fluorescent dye testing as well as independent ultrasonic examination of composites and testing procedures concerning hardness and pressure.



Material testing – make or break

Material testing – make or break

We internally calculate dynamic and static mechanical properties. We are well-equipped for analysing development or real components with our wide range of instruments for tension, hardness, bending and torsion testing as well as measurement sensors for pressure, force and displacement.

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Highest quality demands extensive material testing. This is crucial in both the development stage and during quality assurance. We do not involve external providers which is how we can cut costs and increase flexibility. Your advantages - besides highest quality standards - are prompt availability and favourable prices.

Standard methods we apply are: testing of CFRP monocoques at the torsion testing facility; process validation of welding technologies during tensile testing; controlling of heat treatment processes during hardness testing.

Application examples:

  • DTM-Monocoque, torsion testing
  • High-performance heat exchanger for endurance racing, validation of welding process

Infrastructure:

  • EMCO-TEST hardness testing machinery (Rockwell, Brinell, Vickers)
  • Tensile testing facility
  • Torsion testing facility
  • Bend testing faciltiy
  • HBM measurement sensors for pressure, force, displacement with digital evaluation
 
 


 
Gerg Group