Automotive
Automotive manufacturers face increasing pressure to make vehicles lighter, more efficient, and more environmentally friendly—without compromising safety or performance. Felss supports leading OEMs and suppliers worldwide in meeting these challenges.
Our technologies are designed to manufacture components with exceptional precision and strength while reducing material usage. The result? Components that not only minimize environmental impact but also offer outstanding cost-efficiency.
With our expertise in rotary swaging and other cold forming technologies, we are helping to shape the future of mobility—reliably, innovatively, and efficiently.
Challenges in the Automotive Industry
- Felss Solutions
The automotive sector is undergoing a major transformation: Vehicles must become lighter, more efficient, and more sustainable to meet environmental standards and conserve resources—all while meeting stringent safety and cost requirements.
Felss meets these demands with
innovative manufacturing technologies:
With Felss, you gain a partner that understands the trends and challenges of the automotive industry—and delivers tailored, forward-thinking solutions.
Lightweight design through material efficiency
Rotary swaging reduces component weight without compromising stability.
Precision and durability
Our technologies produce highly accurate and robust parts—ideal for demanding applications.
Sustainable production
Resource-conscious processes reduce material waste and support recyclable design strategies.
Cost-efficiency
By integrating multiple production steps into a single process, we reduce production costs and increase efficiency.
Felss Solutions for the Automotive Industry
Felss-manufactured components contribute to greater efficiency, safety, and sustainability in vehicles around the world. Our innovative processes—including rotary swaging, axial and radial forming—enable the precise production of lightweight components that meet the growing demands of the automotive sector.
Efficient Components for E-Mobility
Lightweight construction is essential in electric vehicles to extend range and reduce mass. With our technologies, we produce:
Hollow rotor shafts
Precisely formed via rotary swaging, reducing weight and improving drivetrain efficiency.
Hollow drive shafts
Material-efficient manufacturing saves raw materials without compromising strength or performance.
Technical advantage
Minimal material use with maximum dimensional accuracy thanks to precision forming.
Drive Systems – Maximum Performance at Minimum Weight
Components like hollow drive shafts and axle journals must balance low weight with high rigidity and long service life. Our technologies offer:
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.
Durability
Forming without weld seams enhances structural integrity.
Precision in Steering Systems
For steering shafts (inner and outer) and steering spindles, Felss combines precision with efficiency:
Rotationally symmetric forming
Millimeter-level tolerances for perfect fit.
Long-lasting performance
High-strength components that meet critical safety requirements.
Flexibility
Customization to meet specific customer needs and vehicle platforms
Optimized Transmission Components
Transmissions endure high stress. Felss-formed parts such as hollow transmission shafts, sun shafts, and input hubs offer:
Reduced mass inertia
Hollow geometries improve power transmission and reduce energy consumption.
Targeted reinforcement
Material is strategically placed where strength is needed most.
Process integration
Combining steps into one streamlined process increases manufacturing efficiency.
Your Advantage with Felss
Our forming technologies unite top-level precision, resource efficiency, and economic value. Whether for e-mobility, powertrains, or transmission components—we deliver solutions tailored to the evolving needs of the automotive industry.
Technologies That Drive Progress
With axial forming, rotary swaging, and flow forming, we manufacture components that are precise, efficient, and economical. Felss technologies provide reliable solutions for complex automotive applications.
Axial Forming
Ideal for components with symmetrical geometries along their axis:
- Steering shafts and spindles: High precision and strength for safety-critical systems.
- Hollow transmission shafts: Reduced wall thickness with optimal durability. Benefit: Axial forming minimizes material usage and post-processing time.
Rotary Swaging
Used to form rotating parts with precision and uniformity—critical for high-stress applications:
- Hollow drive shafts: Maximum strength with minimal material input.
- Rotor shafts for e-mobility: Reduced weight improves range and efficiency. Strength: Uniform material distribution and accurate geometries ensure long-lasting performance.
Flow Forming
Best suited for solid or semi-solid components with complex geometries:
- Sun shafts: High dimensional accuracy and optimized torque transmission.
- Input hubs: Precision-formed parts capable of withstanding high loads. Unique feature: Multiple operations in a single process save time and cost.
Process Integration
By combining axial forming, rotary swaging, and flow forming into one integrated process, we develop components precisely tailored to your requirements—while minimizing material usage and production time.