Automotive
The demands on the automotive industry are constantly increasing: vehicles must become lighter, more efficient, and more environmentally friendly, without compromising on safety or performance. Felss supports leading OEMs and suppliers worldwide in meeting these challenges.
Our technologies are designed to produce components with exceptional precision and strength while saving material. The result: parts that reduce the environmental footprint and deliver clear economic benefits.
With our expertise in rotary swaging and other cold forming technologies, we are shaping the future of mobility – reliably, innovatively, and efficiently.
Challenges in the automotive industry
- Felss solutions
The automotive industry is undergoing a profound transformation. Vehicles must be lighter, more efficient, and more sustainable to meet environmental regulations and conserve resources—all while ensuring maximum safety and cost-effectiveness.
Felss meets these challenges with
advanced forming technologies:
With Felss, you gain a partner who understands industry trends and provides tailored solutions that are reliable, flexible, and future-oriented.
Lightweight design through material efficiency
Rotary swaging reduces component weight without compromising strength.
Precision and durability
Our technologies produce highly accurate and robust components, ideal for demanding applications.
Sustainable production
Resource-efficient processes minimize material waste and support recyclable designs.
Cost-efficiency
By integrating multiple production steps into a single process, we lower production costs and improve overall efficiency.
Felss solutions for the automotive industry
Components manufactured with Felss technologies contribute to greater efficiency, safety, and sustainability in vehicles worldwide. Our innovative processes, such as rotary swaging as well as axial and radial forming, enable the precise production of lightweight components that meet the increasing demands of the automotive industry.
Efficient components for e-mobility
Lightweight design is crucial in electric vehicles to extend driving range and reduce overall mass. With our technologies, we manufacture:
Hollow rotor shafts
Precisely formed using rotary swaging, these components reduce weight and increase the efficiency of electric drives.
Hollow drive shafts
Material-efficient manufacturing saves raw materials without compromising strength or durability.
Technical advantage
Minimal material use with maximum dimensional accuracy thanks to precision forming processes.
Drive systems – maximum performance at minimum weight
Hollow drive shafts and axle journals must combine low weight with high strength and long service life. With Felss forming technologies, you benefit from:
Material savings
Up to 30% weight reduction per component through targeted material distribution.
NVH optimization
Reduced noise and vibration for improved driving comfort and acoustic performance.
Structural integrity
Forming without weld seams maximizes structural strength.
Precision in steering systems
For inner and outer steering shafts as well as steering spindles, Felss delivers precision combined with efficiency.
Rotationally forming
Millimeter-level tolerances for perfect fit.
Durability
High-strength components that meet the most demanding safety requirements.
Flexibility
Solutions tailored to specific customer requirements and vehicle platforms.
Optimized transmission components
Transmissions face extreme stress. Felss-formed parts such as hollow transmission shafts, sun shafts, and input hubs provide:
Reduced inertia
Hollow geometries enable more efficient power transmission and lower energy consumption.
Precise material distribution
Material is placed precisely where maximum strength is required.
Integrated processes
Multiple operations combined into one streamlined process increase efficiency and reduce costs.
Your advantage with Felss
Our forming technologies combine maximum precision, resource efficiency, and cost-effectiveness. Whether in e-mobility, drivetrain systems, or transmission components, we deliver tailored solutions that meet the evolving demands of the automotive industry.
Technologies that drive progress
With axial forming, rotary swaging, and rolling, we manufacture components with precision, resource efficiency, and cost-effectiveness. For the automotive industry, Felss technologies deliver tailored solutions for demanding applications.
Axial forming
Ideal for producing components with symmetrical geometries along their axis:
- Steering shafts and spindles: High precision and stability for safety-critical applications.
- Hollow transmission shafts: Precisely formed with reduced wall thickness and high durability.
Rotary Swaging
Perfect for forming rotating parts with precision and uniformity – essential for high-load components.
- Hollow drive shafts: Maximum strength with minimal material consumption.
- Rotor shafts for e-mobility: Reduced weight for greater efficiency and extended range.
Rolling
Our HMP rolling technology is particularly suitable for solid and semi-solid components as well as for wires and strips where tight tolerances, excellent surface finish, and high strength are required.
- Shaped and flat wires for connectors, contacts, and springs.
- Precision strips for electrical and electronic vehicle components.
Combination of processes
By integrating axial forming, rotary swaging, and rolling into one process, we develop components that are precisely matched to your requirements while minimizing material use and production time.