Challenging times require new developments. Calls for greater flexibility, higher production output and simultaneous relief for skilled workers are growing louder. WAFIOS addresses these issues and offers solutions through automation, flexible production starting from batch size 1 and a bending system for plastic tubes. From now on, all series machines will also be equipped with an AI-based expert system for active operator support. On April 13 - 17, 2026, WAFIOS will present a broad range of these innovations at the wire & Tube show.
Efficient retooling thanks to quick change of tools
WAFIOS will present technical solutions at the Tube show that make daily production easier and increase flexibility. Tool changing systems have been established on the market for quite some time now. Particularly in the area of contract manufacturing or the production of small batch sizes, quick and uncomplicated changeovers are an important factor for smooth production.
WAFIOS’ advanced solution for quick bending tool changeover prevents downtime caused by time-consuming manual changeovers. Now, this solution even includes the change of the bending die. It offers a convenient plug-in system. No more tedious unscrewing of screws. This reduces setup times to a minimum. The tool is available for all tube bending machines of the RBV and TopBend series. At the Tube show, visitors can try out the new feature directly at the TopBend 35.
Flexible prototype production of plastic tubes on the HotBend 35
From short setup times to peak adaptability in the plastics sector: the HotBend 35 is a machine for bending the most different geometries. It employs the flexible CNC technology for the bending of plastic tubes. Therefore, a defined process of heating, bending, supporting and cooling is required. The HotBend 35 does not heat the entire tube but only the area where the bend shall be made. A heating device was specifically developed for this purpose. It can heat different materials, like e.g., PA 12. The tube length to be heated can be adjusted simultaneously. Thus, only the area that shall be formed will lose its rigidity. The tube is handled by a fully integrated robot. During the bending process, an internal mandrel supports the plastic tube from the inside and thus prevents the material from sagging. Bending the tubes with an internal mandrel allows thin tube walls and small bending radii with a homogeneous cross-section and a smooth inner surface of the tube that reduces pressure drops of the fluids flowing through the tubes. The radius of the bend can thus be just as small as the outer diameter of the tube. In addition to the flexible machine, there are also series cells available for the production of plastic tubes in large batch sizes.
Individual automation solutions made by WAFIOS
In addition to tool solutions that make work easier, there are also innovative developments in the field of automation. WAFIOS Tube Automation (WTA) presents a compact punching and embossing machinery system with an integrated handling robot for the production of formed tube parts used in gardening tools. The robot is responsible for all handling operations between the individual units and thus ensures an automated and reliable production process. This machinery system stands out for its high level of flexibility: It enables the processing of different materials as well as the production of different punching and embossing geometries. The solution shows how WTA implements individual automation concepts in various levels of expansion.
Quick production that starts at batch size 1
The TWISTER² 35 shows an automated solution for production that is put to use from the very first part produced. The WAFIOS tube bending machine with an integrated robot is an innovative solution for the automated bending of different tube dimensions that does not require any retooling. This means that a wide variety of tube geometries can be produced in any order, even if only one piece has to be produced, as is required in the hydraulics industry, for example. In the magazine, the different tubes are detected by a camera and the corresponding bending program is selected automatically. The bending tool is designed in such a way that different tube diameters can be processed without changing tools. The TWISTER² offers clear advantages: It enables a flexible adjustment of the bending sequence, there is no need to follow a strict order. Thus, extremely complex, three-dimensional workpiece geometries can be produced with great accuracy. After bending has been completed at one end, workpieces can be further bent from the opposite end. Therefore, tube geometries with very short initial lengths can be produced, even in combination with large bending angles. These parts can be produced ready-to-use without the need for subsequent trimming.
WAFIOS Assistant for super easy setup of new parts
Precise adjustment of a machine often requires sensitivity and experience. Day after day, qualified specialists use their knowledge to help keep production processes stable and efficient. However, identifying problems takes time, as does setting up the machines correctly ‒ an effort that is becoming a challenge in times of increasing skilled labor shortages. This is where modern systems like the WAFIOS Assistant and myWAFIOS.ai step in.
The new WAFIOS Assistant helps in the setup of the machine and supports operators with instructions, images and videos. This will make it much easier to set up complex parts as well. In addition to the setup processes provided by WAFIOS, operators have the option to create their own, individual assistance processes and so help to ensure that the machines are set up consistently within the company. The company's internal know-how is easy to multiply with the WAFIOS Assistant and stays in-house.
In a nutshell: The WAFIOS Assistant supports operators actively in the programming of their machines. It guides them intuitively through the entire operating system and automatically generates suitable machine programs based on templates. A real milestone in the programming of complex machines.
We do not talk about AI – we use it: Operator support with myWAFIOS.ai
At the wire & Tube show 2026, the new AI function myWAFIOS.ai will celebrate its world premiere. For about four years now, WAFIOS has been developing intelligent systems for providing information from documents. Based on this, myWAFIOS.ai was developed. AI helps operators with know-how about the machines and answers questions regarding problems concerning e.g., setup, troubleshooting and retooling. AI can be used on any mobile end device while it is hosted by secure German servers. The machine, with its sensitive production data, does not need an internet connection.
The AI retrieves information from WAFIOS manuals, tutorials and machine plans as well as from experienced WAFIOS operators and service technicians. Also frequently occurring problems and their solutions are available to AI. This guarantees that answers are only generated from trustworthy sources. A patent-pending communication system transmits data in a secure way via an optical QR code with offline link. Therefore, cyber-attacks on the machine are impossible. A great advantage is that myWAFIOS.ai can answer in different languages. This makes it a practical aid that is immediately available internationally.
