Innovation Days 2025

The BM 36 HS is a high-speed wire bending machine that provides a great deal of freedom during the bending process. The high-end bending machine, equipped with intelligent software, optimizes all bending programs fully automatically based on its digital twin.

• High degrees of freedom when bending complex parts

• Simplified input of tools & material

• The servomotor-driven displacement of the feed unit enhances the quality of parts and offers highest degrees of geometrical freedom due to variable bend-back clearances

• EasyRobot takes over handling tasks, no in-depth programming knowledge required

iQ Functions

• iQsmartbend: Quality and performance enhancement through automatic optimization of bent parts
• iQtorque: Workpiece and tool breakage control via monitoring of motor torques

• Automotive
• Furniture industry
• Shopfitting
• Plumbing
• Household appliances

The F 18 compression spring machine is the successor to the EcoCoiler F2 and is part of the Performance series.

• High degrees of freedom when bending complex parts

• Simplified input of tools & material

• The servomotor-driven displacement of the feed unit enhances the quality of parts and offers highest degrees of geometrical freedom due to variable bend-back clearances

• EasyRobot takes over handling tasks, no in-depth programming knowledge required

• Automotive
• Furniture industry
• Shopfitting
• Plumbing
• Household appliances

The compression spring coiling machine FUL 26+ belongs to the most efficient WAFIOS machines. The 4speed option makes the FUL 26+ the fastest spring coiler worldwide. Water-cooled motors enable feed speeds of 600m/min.

• Pay-off units of the AHT and AHP series process wire from wire coils and wire spools reliably.
• Highest dynamics due to new, water-cooled drive technology, for an increased output and reduced unit costs.
• Pay-off units in the AHT and AHP series, featuring an increased load-bearing capacity and designed for wire feed speeds of up to 600 m/min, reliably process wire from coils and spools.
• The wire buffer box compensates fluctuations between the wire coiling machine in start/stop operation and the pay-off unit in continuous operation. The wire enters the connected machine free from tension.
• Innovative and modern machine design with enhanced ergonomics

iQ Functions

• WVS Comfort: iQcontrol & iQopticut: Combines the in-process control of the spring length, end position and diameter with the camera measurement when using the flying rotating cut

• Consumer goods
• Technical components

The FUL 36+ is a compression spring machine with high output and high flexibility. As an option, the FUL 36+ is available as a HighSpeed machine. Their water-cooled drive system and an innovative wire buffer concept enable maximum feed speeds.

• Simplified input of spring geometries
• Equipped with the PTPduo coiling finger, adjustable on the longitudinal and cross axis
• User-friendly equipment including e.g. 3rd and 4th shape axis, PTPduo coiling finger and Multi-E Cut

iQ Functions

• iQspring2FUL: An external measuring device measures the spring and calculates the necessary support points
• iQautopitch: Automatically corrects the pitch by comparing actual with reference values
• iQbestspeed: Calculation of the optimal feed speed
• WVS Comfort: iQcontrol & iQopticut: Combines the in-process control of the spring length, end position and diameter with the camera measurement when using the flying rotating cut

• Automotive
• Consumer goods
• Medical products
• Technical components

The FUL 76 is a compression spring machine with high output and high flexibility.

• Torque (Ve = 130 m/min) and speed mode (Ve = 150 m/min): Adapts the torque or speed based on the drive load
• Configuration of machine ensures fast production of springs due to high feed speed, axis acceleration values, and very short cutting times
• Future-oriented machine concept with the latest drive and control technology
• Convenient WPS 3.2 EasyWay programming system with simplified spring input
• High quality standards ensure zero-defect production
• PTP coiling finger for regulating initial tension

iQ Functions

• iQspring2FUL: An external measuring device measures the spring and calculates the necessary support points
• iQautopitch: Automatically corrects the pitch by comparing actual with reference values
• iQbestspeed: Calculation of the optimal feed speed
• WVS Comfort: iQcontrol & iQopticut: Combines the in-process control of the spring length, end position and diameter with the camera measurement when using the flying rotating cut

All kinds of compression springs and extension spring strands for sectors such as automotive, consumer goods, medical devices, technical components.

The FMU 20+ is a universal spring and wire forming system with enhanced performance and operating convenience. The FMU 20+ can produce springs with machine (German) loops.

• Numerous options for high flexibility and operating convenience
• Convenient programming of complex spring geometries
• High quality standards ensure zero-defect production
• New bending process with two bending pins, familiar from wire bending machines. Rapid bending without repositioning the bending pin
• ModularLoopConcept: Enables the production of springs with standardized machine (German) and crossover (English) loops

iQ Functions

• iQspring+: Automation of the setup process to prevent collisions and to increase the output

• Automotive
• Consumer goods
• Medical goods
• Technical components

The new MULTI-FMU 32 is a modular machine for the production of extension springs with extended loops. Machine produces springs using the mandrel coiling technique. The MULTI-FMU 32 produces extension springs with extended loops and as well as machine (German) and crossover (English) loops.

• Transfer system transports the springs from one station to the next
• Modular structure for high flexibility
• Number and function of workstations is freely configurable
• Simple programming with WPS 3.2 EasyWay and high production output

• Automotive
• Consumer goods
• Technical components

The spring end grinding machine G 450 grinds both compression spring ends simultaneously using the crush-grinding or down-feed grinding technique. It combines e.g. infinitely adjustable cutting speed, automatic dressing and spring length measuring.

• Laser sensors for automatic compensation of grinding wheel wear
• High-end control system WPS 3.2 EasyWay with an automatic generation of programs guarantees optimum production conditions
• Spring length measuring device guarantees a reliable production process
• Noise-reduced protective hood

• Grinding of different spring sizes

The BMF 90 is a high-end wire bending machine for the production of busbars. Thanks to a specially designed bending tool, it provides maximum precision, even when processing the smallest bending radii with minimum bending distances.

• Developed specifically for e-mobility and the production of busbars
• Optimum cutting quality thanks to special cutting unit
• Intuitive and simple programming system for quickly adjusting geometries
• Mechanical insulation stripping as well as laser stripping possible
• Unique twisting device enables the production of complicated bending geometries
• For processing flat copper and aluminum wire

iQ Functions

• iQconvert: Automatic conversion of CAD data to WPS geometry programs
• iQtorque: Workpiece and tool breakage control via monitoring of motor torques
• iQwire: Software add-on for simulating the bending process with flat wire

E-mobility, particularly for the production of busbars

Medium-frequency chain welding machine of the KEH series for resistance butt welding round steel link chains Increased safety and operating convenience.

• Consequent use of servotechnology
• Servodrive of the control shaft with individually adjustable rpm numbers for welding, deburring, and transport
• Upsetting system with integrated pre-stroke
• Chain is transported and rotated up/down via an electric servo-axis
• Robust machine design for the production of high-strength chains over a long period of time
• Reduction of set-up and tooling times due to parameter database
• Use of a medium-frequency transformer and inverter to combine reduced welding time or welding energy with high quality

Chains for heavy-duty hoist, food processing companies

R 36 with end working device EBF for defined chamfering of one or both rod ends.

World first: Assists the operator in setting the machine up and eliminating errors in the straightness, surface, cutting length and cutting quality of rods.

R36

• NEW – The Assisted Machine enables user-guided setup and troubleshooting by means of instructions and pictures
• Control panel with multitouch display allows the convenient input of the wire diameter, cutting length, number of pieces as well as settings such as roller pressure, rotor speed, feed speed etc.

EBF

• NEW - Rod position detection with automatic adjustment of the chamfer size
• Separate drives for advance feed and chamfering spindle; therefore, different chamfers / advance feeds are possible at the rod ends. The higher spindle speed and spindle advance feed rate also increase the range of chamfers
• Optimized operability by simplified adjusting and positioning of chamfering units
• Operation of the EBF via straightening machine

Welded grating, shopping carts and baskets, display items, white goods, cages, metal filters, and many more

The R 45 is a straightening and cutting-off machine for optimum straightening quality and maximum productivity. The R 45 offers new technical solutions for increasing output in a precise and cost-optimized manner. The optionally available, enhanced displaceable stop make it a high-performance machine.

• Displaceable stop:
  • Enables the automatic processing of job lists and placing of rods of different wire lengths and numbers into stations
  • Integrated electrical contact for monitoring the production and preventing the production of too short rods
  • Length tolerance +/- 0.3 mm/m
  • Traversing speed of stop 120 m/min max.
  • Transfer of job lists in combination with OPC-UA interface option
• Motor-driven opening and closing of the protective hood via two buttons on the control panel
• Control panel with multitouch display allows the convenient input of the wire diameter, cutting length, number of pieces as well as settings such as roller pressure, rotor speed, feed speed etc.

Welded grating, shopping carts and baskets, display items, white goods, cages, metal filters, and many more

The TopBend 35 is a right- and left-bending machine for tube diameters up to 35 mm.
The machine is also available as an Eco version, if only one bending direction is required. The second bending direction can be retrofitted at any time.

• Available as EcoBend with one bending direction, can be upgraded to TopBend on request mixed
• Very high operating speed due to unique bending kinematics and performance-optimized design Design
• Up to three tool levels (right and left) can be used for 35mm tube Ø
• Second tube stop at the tube gripper end extends the tube processing length by 1,300 mm (manual loading)
• Swiveling mandrel bending device
• Rotary-draw bending and free-form bending is possible
• Fully integrated loading concepts and magazine solutions feed the material efficiently (optional)

iQ Functions

• iQbend: Reduction of setup work due to simple adjustment of  bending speeds
• iQconvert: Automatic conversion of CAD data to WPS geometry programs
• iQfreeform: Optimization of set-up times through simplified programming of free-form geometries
• iQinspect: Automatic correction of components by means of an external measuring device
• iQtorque: Workpiece and tool breakage control through monitoring of the motor torque
• iQtube: Simulation of the bending process with collision monitoring and determination of cycle time
• iQtube+: Automation of the setup process to prevent collisions and to optimize the position of the table
• iQtubeorientation: Automatic positioning of tubes with punched-in holes and markings before the bending process

Air conditioning technology, furniture, automotive, aerospace, rehabilitation technology

The RBV 25 R KSB is a powerful, high-performance tube bending machine for tube diameters between 1 and 25.4 mm. State-of-the-art drive technology with energy recovery guarantees highly efficient machine operation.

• Dynamic bending head movements and mass-optimized machine design
• High flexibility and short setup times when setting up new parts
• KSB version for the flexible CNC bending of head rest tubes and seat adjustment tubes and for integration into a production line

iQ Functions

• iQbend: Reduction of setup work due to simple adjustment of  bending speeds
• iQconvert: Automatic conversion of CAD data to WPS geometry programs
• iQfreeform: Optimization of set-up times through simplified programming of free-form geometries
• iQinspect: Automatic correction of components by means of an external measuring device
• iQtorque: Workpiece and tool breakage control through monitoring of the motor torque
• iQtube: Simulation of the bending process with collision monitoring and determination of cycle time
• iQtube+: Automation of the setup process to prevent collisions and to optimize the position of the table

Air conditioning technology, automotive, aerospace, rehabilitation technology

The RU 60 is an endforming machine for tubes and solid material with a forming force of 600 kN and one forming step.

• Servo-hydraulic forming drive with 18 l oil reservoir
• For tubes and solid material with adjustable diameter
• Combined travel and force control with pressure accumulator
• Operation via tablet
• Can be operated automatically, integrated in production cells or as stand-alone machine
• Cycle time reduced by 30%
• Less than 3 seconds per part with one forming step
• New kinds of forming processes save material by thickening the tube wall
• Reduction of energy consumption by 45% due to the elimination of bulky hydraulic systems

Automotive industry and their suppliers, machinery and electrical industry, airconditioning, sanitary and heating industry, furniture and lighting industry