Red 2025

Driving E-Mobility to the next level!

Experience the latest machines and technologies for hairpin stators, axial flux motors and busbars up close. Talk to our experts from the industry and listen to interesting lectures on current R&D and production topics regarding batteries and electric motors!

We look forward to presenting our innovative solutions to you and to answering all your questions.

Werk2_Reds
Venue:
E-Mobility Campus, Plant 2
Wafiosstraße 1,
72766 Reutlingen

Take a look at our new E-Mobility Campus

TimeNameLecture/ Session title
11 a.m. Dr.-Ing. Uwe-Peter Weigmann (WAFIOS AG), Bernd Nagel (Gehring) Welcome address and opening of 6th Reutlingen E-Mobility Days
  Prof.-Dr. Neijla Parspour (Stuttgart University) Keynote presentation
     
2 p.m.Technical Session 1:Next Level off-highway Electrification
  Prof. Tatiana Minav (Tampere University) Benefits of electric motors in working machinery
  Dr.-Ing. Bernhard Burkhart (Engiro) Leveraging Modularity in Mobile Machinery for Competitive Efficiency and Cost
  Nathalie Tege (WAFIOS), Dr. Andreas Wiens (Gehring) From idea to product - flexible Hairpin Stator Prototyping made by WAFIOS + Gehring
TimeNameLecture/ Session title
10 a.m.Technical Session 2:Next Level Electric Motors
  Michael Southcott (S&P Global) The Global Evolution of the Electric Motor Supply Chain and Technology Development
  Dean Petrovski (DeepDrive) Application of a Dual Rotor, Radial Flux In-Wheel Motor in Electric Vehicles
  Tbd. To be announced soon
     
11.30 a.m.Technical Session 3:Next Level Battery Production
  Florian Kößer (KIT) Modular Plant Construction Kit for the Automated Manufacturing and Disassembly of EV-Batteries
  Thomas Mayr (Intercable) Standardization of Busbars in the Automotive Industry: Aligning Requirements to Drive Innovation and Integration
  Frank Fauser (WAFIOS) Innovations in Busbar Production
     
2 p.m.Technical Session 4: Next Level Winding materials
  Moritz Stöckler (PEM) Understanding Insulation Testing
  Volkmar Platte (Elektrisola) Understanding Litz Wire
  Lea Bünger, Paul Baek (EVONIK) Understanding Polymers
TimeNameLecture/ Session title
10 a.m.Technical Session 5:Next Level Axial Flux Motors
  Tbd. To be anncouned soon.
  Uwe Köhler (Lambda Resins) Alternative cooling solutions for Axial Flux Motors as enabler for a cost revolution.
  Robert Haman (Nagel) Building the next generation of Axial Flux Motors - how to reach a cycle time of 40s!
     
11.30 a.m.Technical Session 6:Next Level Battery Development
  Dr. Hartung Wilstermann (Webasto) Presentation title to be anncounced soon
  Dr. Alexander Kohs (Bertrandt) AI and Digital Twins as Enabler for efficient Battery Development
     
2 p.m.Technical Session 7:Next Level Joining Technology
  Felix Wirthmann (FAPS) Advanced connection technology in modern energy transmission
  Matthias Beranek (TRUMPF) On the Way to Fully Adaptive Lasersystems with Maximum First Pass Yields for Hairpin Design Stator Manufacturing
  Karim El Rikabi (Strunk) Resistance welding of Al and Cu – mission completed

Our Co-Exhibitors

Logo WAFIOS
Logo Gering
logo Nagel Technologies
Logo KIT
Logo hailtec
FAU_FAPS_Logo
Logo RWTH-AACHEN
Logo HPW
Logo Hexagon
Logo Standard Metallwerke
Logo ElringKlinger
Hyperdrives
image-29456
Logo Lambda Resins
Logo Trumpf
Logo coiltech
Logo Uni Stuttgart
Logo marposs
Logo Strunk Connect
Logo KEYENCE
Logo Schunk Sonosystems

Take Part in the REDs 2025!

Opening hours Tuesday 9:00 a.m. - 5:00 p.m.

I am planning to visit on:

Please check interests

All fields marked * are mandatory and must be completed.

Exhibition Program

WAFIOS AG

World premiere: BTF 90-2 – a pioneering machine concept for economical production of long busbars such as complex charging lines

  • Two bending heads with a proven tool concept plus a twist function make it possible to process busbars at both ends while maintaining outstanding bending quality standards and output. 
  • The modular machine concept is able to process not only rod material from magazines, but also coil material in conjunction with pay-off units and wire straightening and cutting machines. Developed for a material cross-section of up to 400 mm² at 100 N/mm² and a component length of up to 3,000 mm.

 

New Solutions for Hairpin Stators and Axial Flux Motors:

  • Tool and software solutions for shorter cycle times and reduced costs in hairpin production
  • Live demonstrations of several FMU 40E + SpeedFormer machines
  • New concepts and production methods for coils
  • Presentation of concept for series production of axial flux motors

BM 36 High-Speed in combination with CNC-controlled FSA 2.5 insulation stripping device – the economical solution for manufacturing electrical components from enameled copper wire  

  • The combination of the BM 36 HS and FSA 2.5 for bending complex geometries and stripping contact surfaces on component ends with high precision is ideal for applications such as series production of stator connection assemblies.

Gehring at REDs in Reutlingen

Gehring stands for technologically innovative solutions, extensive expertise in production technology for the electric powertrain, and decades of experience as a system supplier for OEMs and Tier 1 customers in the automotive and supplier industry.

Our integrated portfolio covers production technologies for the series manufacturing of traction drives in electrified vehicles – both based on hairpin technology and in the field of axial flux stators. In this way, we support the industry in its transformation towards future-oriented drive concepts.

With shorter product life cycles, the focus of our solutions is on higher productivity, optimal utilization of equipment, and greater flexibility. In our technology center, motors are tested on production-like original equipment in advance, ensuring a faster and more efficient transfer to series production. Strict quality controls are applied after each process step. For this purpose, we rely on state-of-the-art measuring technologies and test methods. A central element here is the Gehring Inspection System (GIS) – an intelligent quality assurance solution that provides precise measurement data, guarantees seamless process monitoring, and ensures complete documentation.

Another key focus is our prototype production. In close collaboration with our customers, we develop and manufacture prototypes and pilot stators – for both hairpin and axial flux designs. The goal is to achieve short lead times and reduced manufacturing costs. At the same time, valuable process know-how gained in prototype production can later be transferred to series applications.

Our core competencies include:

  • Pin insertion
  • Expansion
  • Twisting
  • Cutting to length
  • Laser welding
  • Impregnation
  • Powder coating
  • Stator measurement

Visit us at REDs in Reutlingen and learn more about our innovative solutions for the future of mobility.

NAGEL


Maschinen- und Werkzeugfabrik GmbH

Machines for battery and electric motor production
Assembly solutions for axial flux motors

Bonding and sealing

  • Robot based adhesive application
  • Sensor based quality monitoring
  • Assembly and joining processes
  • Flexible stand-alone systems
  • System integration in production lines according to OEM standard

Potting

  • Potting processes in atmosphere or vacuum
  • Highly filled potting materials
  • Potting of stators for electric motors

Engineering

  • Mechanical and plant engineering
  • Robot integration and simulation
  • Path generation and optimization / digital twin
  • Turnkey plants and process engineering

Service

  • Technical center for samples and contract manufacturing
  • Process development & prototype production according to customer requirements

Coiltech® 

Electric energy doesn’t move us – unless it goes through a chain.

It starts with generation – as alternators produce current.
It flows through transformation – stepped up, stepped down, routed by transformers.
And it ends in motion – electric motors turning energy into work.

From large grids to the smallest drives, from energy to action – everything depends on how efficiently this chain performs.

And behind it all: winding, insulation, cores, resins, testing, integration – the details that decide efficiency, durability, and progress.

Coiltech exists to strengthen the chain that runs from raw materials to reliable machines. Because when electric motion becomes more efficient, systems improve,
products evolve, and people benefit – from better mobility, smarter energy, and greater sustainability.

From energy to action – everything depends on how efficiently this chain performs.

Coiltech is where that effort aligns.

ElringKlinger AG

Pioneering Mobility. Shaping the Future.

A wide range of ElringKlinger components relating to e-motors, transmissions and inverters can be used in an electric drive unit. The design and materials of all our product solutions are tailored precisely to the relevant requirements – for maximum design freedom and functional reliability.

ElringKlinger supplies MetaloBond™ rotor/ stator laminations, metal elastomer and MetaloSeal™ gaskets, radial shaft seals and housing covers for electric drive units.

MetaloBond™ rotor/ stator laminations

With ElringKlinger’s unique bonding technology, MetaloBond™ ensures best-in-class sealing performance throughout the entire lifetime of laminated rotor and stator stacks. Its exceptional sealing capability, combined with full media and temperature compatibility as well as high mechanical strength, makes MetaloBond™ the ideal solution for demanding direct-cooled applications.

Characteristics:

  • Best-in-class sealing performance for integrated cooling concepts
  • Full compatibility with media and temperature ranges
  • Enhanced mechanical strength and optimized NVH behavior
  • Maximum design flexibility
  • Superior cooling efficiency for increased e-motor performance

Friedrich-Alexander-Universität Erlangen-Nürnberg

Lehrstuhl FAPS

The Institute for Factory Automation and Production Systems (FAPS) at Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU) focuses on the development of innovative manufacturing processes for mechatronic products.

The associated research group for electric machine production focuses on manufacturing processes for electric motors and contactless charging systems. From process development and optimization to recycling, the topic area of electric machine production is covered in a fully comprehensive, future-oriented and sustainable manner. The main areas of research are

Development and optimization of production technologies and processes

  • Development and optimization of production technologies and processes
  • Innovative materials
  • Digitization and data-driven solutions
  • Process automation
  • Recycling and circular economy
  • Process simulation

HAILTEC GmbH


Prototypes in Series Production Quality for E-Mobility

With around 45 employees in the Swabian Alb, HAILTEC specializes in the precise manufacturing of components for e-mobility – from batch size 1 to small and medium series production. Part of the Consydera Electric Division since 2024.

Unparalleled Technology Arsenal: Laser Fine Cutting, Ultra-Short Pulse Laser Processing, Micro Water Jet Cutting, Precision Forming Technology, CNC Precision Manufacturing & Wire EDM, In-house Design & Toolmaking, 3D Metrology

BUSBARS

  • Laser or micro water jet cut
  • Formed via CNC press brake bending
  • Optional surface coating
  • Fast response times for changes or sample requirements

LAMINATION STACKS (STATOR/ROTOR)

Laser fine cutting with tolerances of ±5 μm on robot-equipped dual cutting head systems. Optional with backlack technology, laser welding, etc.

  • Cutting burrs < 3 μm through cold laser cuts
  • Stack accuracy in the μm range
  • Large material inventory for electrical steel sheets (NO10, NO20, etc.)
  • Access to over 35 laser cutting systems of the Consydera Group

HPW Metallwerk GmbH

HPW is a leading manufacturer of winding wires for e-mobility and wind power and is thus one of the key companies in a rapidly growing future market.

As a specialist for PAI and PEEK-insulated copper flat wires, HPW has been a series supplier to numerous renowned European OEMs and Tier 1 manufacturers for several years with three production sites in Austria. A plant in North America for PEEK-insulated copper flat wires is currently under construction and will serve the first large-scale production in the USA from 2027.

As a technology leader, HPW manufactures PA12-insulated busbars with conductor cross-sections of up to 400 mm². The fully automated process covers the entire value-added chain from the raw material made of copper or aluminium to the finished insulated flat conductor. Aluminium busbars in particular meet the increasing demands of automotive customers for weight reduction, tight bending radii and temperature resistance of the insulation.

Hyperdrives

Benchmark electric drive systems

Hyperdrives specializes in developing and producing hollow-conductor cooled electric drive systems that
combine exceptionally high continuous power density and efficiency with lowest-in-class cost.

  • Continuous power density of >12 kW/kg (including SiC inverter)
  • Superior efficiency in partial-load operation
  • Radial-flux hairpin design with distributed winding, adaptable to all rotor topologies
  • Scalable, industrial manufacturing processes designed for seamless integration into existing lines

Karlsruhe Institute of Technology (KIT)

Production Science for Electromobility

The wbk Institute of Production Engineering at the Karlsruhe Institute of Technology (KIT) is developing innovative manufacturing and assembly processes for electric traction motors together with its industrial research partners. Beyond the further optimization of efficiency and power density, the research work addresses in particular the shortening of time-to-market and the reduction of production costs.

The focus of the trade show participation is on flexible production technologies for stators and rotors as well as digital process chains for efficient tool design and intelligent process parameterization:

  • Kinematic manufacturing and assembly processes for fast and flexible prototyping
  • Process models for shaping hairpin plug-in coils as well as insertion, twisting and laser-based contacting of stators with hairpin winding.

Lambda Resins GmbH

Lambda Resins GmbH – casting resins for electric motors

Development and production of thermally conductive casting resins for potting electric motors

Potting compound “Lambdapox”:

  • very high thermal conductivity up to over 8 W/m⋅K
  • low viscosity and good impregnation ability from 1,500 mPas
  • excellent wetting properties and outstanding adhesion
  • no measurable shrinkage during hardening
  • high mechanical strength in the working range up to 180°C
  • reactivity can be adjusted using chemical accelerators
  • thermal class H 180°C
  • high thermal resistance at peaks even above 200°C
  • extremely low thermal expansion coefficient of 8 - 14 ppm
  • no cracking in the thermal shock test from -40 to +180°C
  • very high insulation resistance, at 180°C >1.3 G Ohm
  • fire behavior according to UL94 V0 (in preparation)

MARPOSS

Passion for precision

With 3,500 employees worldwide, the MARPOSS Group is a global technology company and your partner for quality assurance in production control.

MARPOSS develops and manufactures a wide range of products and solutions for quality and process control of all electric powertrain components: e-motors, batteries and fuel cells such as:

  • Hairpinflash 3D: Quick hairpin contour check for production-related testing
  • Horizon: Coating thickness measurement on PEEK wires
  • AST320: Partial discharge measurement for wound goods
  • OptoQuick: Measurement technology for shafts & rotors
  • T3L & TM3-Serie: Leak testing technology

Standard-Metallwerke GmbH

Standard-Metallwerke GmbH (Werl/Germany) - with approx. 450 employees - has been recognised as a reliable partner for precision tubes and fluid line components for more than 100 years. We are established on the market in the automotive industry and other industrial sectors with our semi-finished products, components and rigid busbars. Specialized in the materials aluminium and copper, we also provide products made of steel, stainless steel and composite materials.

Our coating know-how has been perfected over a quarter of a century and allows us to apply various insulation materials to a wide variety of materials by means of extrusion according to customer requirements. In addition to electrical isolation and corresponding mechanical resistance, this also ensures optimum surface protection against aggressive media and abrasion. The special process achieves a strong adhesion of the coating to the conductor material, which enables bending without wrinkling or tearing of the respective coatings with voltage loads of up to 1,000 V.

  • Core materials: aluminum, copper, cupal
  • Coating materials: PA12, PEEK, PPS, XLPE
  • Dimensional range: up to 80 mm x 8 mm
  • Coating thickness: 100 – 1200 µm

Based on our experience in coating technology, we are the pioneers in the field of extruded busbars, which are supplied on coils for further processing. However, we can also provide busbars that have already undergone further processing, which includes cutting to fixed length, end stripping and bending, for example.

Whether as a material supplier or manufacturer of complete system components - we are at your side as a reliable partner with our expertise, from development to series delivery!

Our association within the Wilms Group offers decisive advantages.

STRUNK CONNECT

Your expert in resistance welding solutions for non-ferrous metals & automation!

Our expertise:

  • S2R process: AL busbars to Cu conductors & terminals
  • HC-L process: AL cables & AL enamelled wires to Cu terminals
  • Traditional applications in HV & LV areas: Power distribution via busbar, diffusion welding of copper foils, wire harness (resistance brazing, terminal welding, compacting, splicing, hot crimping and micro welding).

Our solutions are used at: power distribution, high-voltage harnesses, inverter systems, energy storage devices/batteries, electric drives (stators and rotors), stationary and mobile AC/DC charging applications, signal transmission from sensors, and much more.

From tabletop devices to fully automated systems with optional process chaining – we accompany you from product development to finished automation concepts.

Trumpf

Laser Decoating

  • High Power Short Pulse Laser TruMicro with tailored beam profile for high fill factors and top notch processing speeds
  • Fastest processing for all insulation types and layer thicknesses without affecting the conductor material
  • Scalable optics concept individual to wire size

Laser Contacting

  • High Power TruDisk Laser, freely programmable scanning optics PFO and Vision Line Sensor System with artificial intelligence
  • Position and Process Closed-Loop Welding at all Pins enable 100% quality without losses in the conductive connections
  • Welding with low spattering and free of porosities using Bright Line Weld Multi-Spot waveguide
  • Scalable Power- and waveguide concept individual to wire size and parts arrangement as well as for optimizing your machine designs

 

TRUMPF experts individually support in laser process development and realization with all technologies utilizing the know-how of our inhouse process development as well as experience from more than one hundred projects.

University of Stuttgart

Institute of Electrical Energy Conversion (iew)

The Institute of Electrical Energy Conversion (iew) at the University of Stuttgart is an innovative partner for research into high-efficiency electrical machines and contactless energy transmission systems. As a research institute, we develop forward-looking solutions – from initial concept to fully optimized prototype – for applications in medicine, industry and electromobility.

  • Tailored research and development: modeling, design and prototype construction for electrical machines and energy transmission systems.
  • AI-supported optimization: comparative analyses and intelligent design for maximum efficiency and performance.
  • Precise measurement and characterization: comprehensive measurement of magnetic materials and of drive and energy transmission systems.
  • Power electronics and system integration: maximum-efficiency power electronics and their integration for the drive systems of the future.
  • Smart operation: development of ideal operation strategies and reliable error detection.

In addition to studying common motor topologies, we are specialists in the following areas:

  • Rare earth-free electrical machines such as the inductive electrically excited synchronous machine (iEESM)
  • Innovative 3D flux machines (such as axial flux and transverse flux machines)
  • Transmission-integrated multi-drives and intelligent control of them
  • Sustainable drive systems based on modularization and repairability
  • Multi-phase drive systems

Additive Drives

The global Benchmark for customized eDrives

Electrification from a single source: Additive Drives offers the development and production of customised e-drive solutions for the most demanding requirements.

We provide customised solutions for every industry, delivering maximum performance for the most demanding requirements.

High power density: powerful cooling systems and high-performance materials enable power densities of over 120 kW/litre.

We are combining different manufacturing methods enables maximum flexibility in the production of electric motors.

Schunk Sonosystems

Global Leader in Ultrasonic Welding Technology

Your Partner for Innovative Connection Solutions
Schunk Sonosystems GmbH, headquartered in Wettenberg near Gießen, is the global market and technology leader in ultrasonic metal welding. As a Business Unit of the long-established Schunk Group, founded in 1913, the company combines more than a century of experience with cutting-edge technology.

Core Competence and Technology
Schunk Sonosystems develops innovative ultrasonic welding machines that enable metallurgically pure, high-strength connections without additional materials or melting. With the strategic integration of MS Ultrasonic Technology Group, the company expanded its portfolio to include ultrasonic plastic welding and now offers comprehensive solutions for both material groups.

Markets and Applications

Metal Welding (Schunk Sonosystems):

  • Automotive: Precise wire harness connections for cross-sections from 0.13 to 300 mm²
  • Battery Technology: Complete solutions from cell production to battery contacting
  • Power Electronics: Solder-free connections for IGBT and IPM modules with up to 10x longer service life
  • Cooling Technology: Ultra-fast welding solutions for hermetically sealed refrigeration circuits

Plastic Welding (MS Ultrasonic):

  • Medical Technology: Precise, chemical-free connections for medical components
  • Packaging/Food Industry: Sealing, cutting, and welding of films and packaging materials
  • Textile Industry: Welding, punching, and separating of textiles and nonwovens
  • Automotive: Plastic components such as bumpers, door panels, and instrument clusters
  • Consumer Goods: Flexible machines for a wide range of consumer applications
  • Electrical Components: Ultrasonic bonding for electronic parts

Global Presence and Expertise
With over 1,000 employees worldwide, Schunk Sonosystems has a strong international presence. The company operates sites in Germany, Morocco, the USA, Mexico, China, Japan, and South Korea, ensuring optimal customer support and service availability around the globe. Through MS Ultrasonic, additional sites in Germany (Spaichingen, Ettlingen), the USA (Howell), as well as Brazil and China further strengthen the global footprint.

Innovation and Quality
Continuous research and development enable Schunk Sonosystems to set technological standards and deliver tailor-made solutions for the most demanding industrial applications. Modular system concepts, comprehensive process monitoring, and full traceability guarantee maximum quality and productivity.

Hexagon

Smart solutions for eMobility manufacturing

eMobility production has quickly grown to become a key area of modern automotive manufacturing. Hexagon has the ground-breaking metrology and automation expertise needed to understand and deliver solutions to the challenges of e-motors production.

  • TubeInspect 37 M | 37 XL: The 3rd generation of camera-based tube measurement cells for efficient automated quality control of hairpin, busbar, and bent tubes e.g. for hydrogen piping systems
  • Portable measuring arms with 3D laser scanner: Extremely portable solution with good depth capture for measurement of features on small and medium-sized parts
  • BendingStudio XT version 12.0, 2025: Hexagon software for all manufacturing steps in bending process starting with CAD file up to the production of a master part or the production of serial parts, including automated feedback to CNC bending machines

KEYENCE DEUTSCHLAND GmbH

As a technology pioneer in sensors, measurement systems, marking and identification solutions, microscopes, and image processing systems, KEYENCE holds a leading global position in automation and quality assurance technologies.

Highlights for Electric Motor Manufacturing:

2D/3D Laser Profile Sensors (LJ-X8000 Series)
High-resolution inline laser scanners precisely measure gap dimensions, weld seams, and complex geometries already during core manufacturing – including OCR for automatic identification of motor housings.

3D Laser Snapshot Sensor (LJ-S8000 Series)
An integrated scan mechanism – without positioning unit or encoder – enables rapid, high-precision 3D data acquisition within the shortest time. Ideal for monitoring material application on cast housings or for inspecting connection positions of film capacitors.

Inline Profile Projector (TM-X5000 Series)
With double telecentric optics and a large depth of field, the TM-X5000 series enables fast, precise measurement of the diameter and pole height of cylindrical batteries directly in production, at full line speed.

Confocal Displacement Sensor (CL-3000 Series)
Essential for accurate thickness measurements sheet metal stacks and core components after pressing. The quad-processing system ensures reliable, repeatable results, even on rough or irregular metal surfaces.

Your Advantage: Tailored on-site solutions for your electric motor production. Experience precision and innovation at our booth!

RWTH Aachen – PEM

The Chair "Production Engineering of E-Mobility Components" (PEM)

… at RWTH Aachen University was founded in 2014 by "StreetScooter" co-founder Professor Achim Kampker. In ten research groups, the team is dedicated to all aspects of the development, production and recycling of battery systems and their components as well as the fuel cell and the production of the electric drive train and entire vehicle concepts. The research group "Electric Drive Production" contributes to the economic, variant-flexible, future-oriented and sustainable production of the electric drive and its active components (rotor and stator). The focus is on investigating issues along the entire value chain - from the semi-finished product to the finished drivetrain and from the individual process to the holistic consideration of cross-process interactions. In accordance with the PEM philosophy of the "Innovation Chain", the team works on new and innovative technologies, always keeping an eye on the path to industrial application and solution scaling. Current topics of the research group are:

  • Interdependencies between semi-finished product and process in stator production (with special focus on stripping, bending & welding).
  • Development and implementation of application-oriented test and inspection procedures as a basis for demand-oriented products and processes
  • Lifecycle-oriented optimization of production processes and development of measures to identify and reduce the CO2 footprint along the entire value chain
  • Use of AI-based methods for efficient, economical and sustainable electric motor production
Picture of Martin Bauer

Martin Bauer

E-Mobility Sales

Manager - Technical Sales, E-Mobility

 +49 7121 146-219

 ma.bauer@~@wafios.de