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Simplify E-Mobility Production

From November 17–19, discover the latest machines and technologies for hairpin stators, axial flux motors and busbars – live and up close.

See how innovative manufacturing technologies are making e-mobility production faster, more flexible and less complex. From intuitive machine programming and AI-powered solutions to new production concepts, we are simplifying processes and opening up entirely new possibilities for electric motor and battery component manufacturing.

Meet industry experts, exchange ideas and gain insights into the latest research and trends shaping tomorrow’s production.

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

Take a look at our new E-Mobility Campus

Further information on the lecture program, as well as the option to register, will be available shortly.

Our Co-Exhibitors

Logo WAFIOS
Logo Gering
logo Nagel Technologies
Logo KIT
Logo hailtec
FAU_FAPS_Logo
image-32924
Logo Hexagon
Logo ElringKlinger
Logo Lambda Resins
Logo Trumpf
Logo coiltech
image-34809
Logo Strunk Connect
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Logo Schunk Sonosystems

Your contact person

Picture of Martin Bauer

Martin Bauer

E-Mobility Sales

Manager - Technical Sales, E-Mobility

 +49 7121 146-219

 ma.bauer@~@wafios.de

Exhibition Program

WAFIOS AG

Highlights of Hairpin and Coil Manufacturing - Less Complexity, More Productivity

  • FMU 40E with EasyRobot and Spacemouse – Simple and intuitive hands-on robot programming.
  • FMU 40E with die bending technology – Hairpin series production, precise and simple.  
  • Modular tool concept – Maximum flexibility with short tooling times.
  • WAFIOS Hairpin Suite – Intelligent software package for a quicker and easier setup of hairpins.
  • WAFIOS Assistant & myWAFIOS.ai – Digital support for operation, service and maintenance.
  • Straightening technologies – New solutions for laboratory applications and cost-effective series production.

Highlights in Busbar Manufacturing – New Machine Designs for Complex Geometries

  • BMF 90 – Adaptive bending tool and mechanical insulation stripping for highest flexibility.
  • BTF 90-1 in combination with straightening machine RF 90  - With external bending module for economical production of long and complex busbars.
  • TWISTER² 35 RL – Innovative robot technology, combined with precise bending and twisting operations for the production of busbars.
  • WAFIOS Assistant & myWAFIOS.ai – Digital assistance systems for more productivity and operating convenience.

Virtual presentation of more machines

See our latest machine developments, like the BTF 90-2, SpeedFormer, coil production machine and many more, in an interactive virtual-reality presentation.

 

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.

System Expertise for Electric Drive Units

The electrification of the powertrain is driving new requirements for efficiency, integration, and functionality. ElringKlinger develops and manufactures components for key areas of electric drive units, tailored to the specific demands of modern e-mobility applications. From solutions for e-motors, transmissions, and inverters to innovative rotor and stator lamination technologies, ElringKlinger offers a comprehensive portfolio for next-generation drive systems. Visit the ElringKlinger booth and discover how advanced components and manufacturing technologies contribute to modern electric drive units.

MetaloBond™ rotor/ stator laminations

With its unique bonding technology, MetaloBond™ provides best-in-class sealing performance for laminated rotor and stator stacks. Outstanding sealing capability, full media and temperature compatibility, and high mechanical strength make MetaloBond™ an ideal solution for demanding direct-cooled applications.

Characteristics:

  • Best-in-class sealing function enables integrated cooling concepts
  • Full media and temperature compatibility
  • Enhanced strength and NVH performance
  • Maximum design freedom
  • Higher cooling performance, hence increased e-motor efficiency

Friedrich-Alexander-Universität Erlangen-Nürnberg

Lehrstuhl FAPS

The Institute of Factory Automation and Production Systems (FAPS) at the 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 conducts research on manufacturing processes for electrical energy converters such as motors, generators, and inductive power transfer systems. It comprehensively covers the entire spectrum of electric machine production, from process development and optimization to recycling, in a future-oriented and sustainable manner. Key research areas include:

  • Development and optimization of production technologies and processes
  • Innovative product designs and materials
  • Digitalization and data-driven approaches
  • Process automation
  • Measurement technology and quality assurance
  • Circular economy

HAILTEC GmbH


Prototypes in Series Production Quality for E-Mobility

Based in the Swabian Alb region and with approximately 50 employees, HAILTEC specializes in the precision manufacturing of sophisticated components for the e-mobility industry - from single units to small and medium-sized series. Since 2024, HAILTEC is part of the Consydera Electric Division.

Wide range of technologies: precision laser cutting, ultrashort-pulse laser processing, micro waterjet cutting, precision forming, CNC machining & wire EDM, in-house design & toolmaking, 3D measurement technology

Rotor and stator laminated cores made of electrical steel

Laser fine-cutting with tolerances of ±5 µm on robot-automated dual-head cutting systems. Optional with bonding varnish technology, spot bonding, laser welding, etc.

  • Burr < 3 µm using cold laser cutting
  • Stack accuracy in the micrometer range
  • In-house coating using various coating systems for customized insulating and functional coatings
  • Established project experience in laser cutting and bonding of cobalt-iron alloys
  • Extensive inventory of all standard grades of electrical steel (NO10, NO20 up to M800-65A)
  • Access to 35 laser cutting systems of the Consydera Group

Busbars

  • Laser- or micro-waterjet-cut
  • Formed via CNC swivel bending
  • Surface coating available as an option
  • Quick response times for changes or sample requests

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)

Luvata

Copper Hollow Conductors for EV Motors

Luvata is a global leader in custom-made copper hollow conductors, delivering advanced solutions for demanding applications from high-energy physics to electric vehicles. For EV motor manufacturers, we offer small-size and insulated hollow conductors designed for direct stator cooling. By enabling efficient heat removal directly from the winding, our conductors support higher power density, improved efficiency, and more compact motor designs. Manufactured in Finland from high-purity oxygen-free copper, Luvata hollow conductors are available in a wide range of dimensions and can be tailored to meet specific performance requirements.

STRUNK CONNECT

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

Our expertise:

  • S2R process: Aluminum busbars to Cu conductors & terminals
  • HC-L process: Aluminum cables & enamelled Aluminum wires to Cu sleeves/cable lugs
  • 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, energy storage devices & batteries, electric drives (stators and rotors), stationary and mobile AC/DC charging applications, signal transmission from sensors, etc.

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

TRUMPF

Laser Decoating

  • TruMicro high-performance short-pulse laser with an optimized spot profile for high fill rate and high material removal rate
  • Fastest processing for all insulation types and layer thicknesses without affecting the conductor material
  • Scalable optics concept individual to wire size

Laser Contacting

  • TruDisk or TruFiber high-power lasers, freely programmable PFO scanner optics, and Vision Line sensor technology 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
  • Comprehensive solution for all motor topologies: radial and axial flux, U/I/Mini/X pin configurations using copper and aluminum conductors

TRUMPF experts provide personalized support for the development and implementation of all technologies, based on their knowledge gained from their own process development and hundreds of customer projects.

SWD AG

Precision for E-Mobility

SWD AG develops and manufactures fully automated, high-precision stator stacks for modern electric drive systems. With extensive expertise in materials, processes, tooling, machinery, and data, we achieve the tightest manufacturing tolerances and the highest quality standards.

Our core competencies:

  • Engineering support from component development to industrialization
  • Seamless scaling from prototypes to high-volume production
  • High-precision electrical steel stacks for electric motors
  • Proven expertise in tight tolerances and complex geometries
  • Automated manufacturing processes for maximum repeatability
  • Scalable series production for international automotive and industrial customers

At our exhibition booth, we will present innovative solutions for the efficient and precise manufacturing of components for the next generation of electric drive systems.

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
  • Absolute Arm with 3D laser scanner: Extremely portable solution with good depth capture for measurement of features on small and medium-sized parts
  • BendingStudio XT version 13.0, 2026: 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.

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