Prototypes Small Series: supplier of stamped and bent parts
Fast and reliable: Prototype construction for small bent parts
Your expert for filigree sheet metal prototypes, small series & pre-series
With sheet metal prototypes, you have no time to waste. Do you need small bent parts? Trust us for development and production: From feasibility analysis to surface finishing, we handle everything in-house and never share your drawings or data. With modern CAD/CAM design, in-house toolmaking, and a unique technology mix, we implement your requirements with agile prototype production. And we do this efficiently for quantities from 1 to 500.000 – thanks to lean, automated processes and highly qualified personnel.
Filigree and precise sheet metal prototypes small series
Product ideas and manufacturing examples from HAILTEC
Leaf springs, shaped springs, etc.
Busbars
Sample prototyping: What are the advantages of manufacturing for you?
Advantages: Prototype construction & small series from HAILTEC
As a lean development partner with a special range of technologies, we can produce your smallest bent parts even under time pressure.
You benefit from the ideal cutting and forming technology at every stage, because we have all the relevant equipment in-house.
Vertical integration
Do you need an initial sample or a reproducible series? HAILTEC's extensive vertical integration is your advantage. You always benefit from the technically and economically ideal process for prototype production or series production.
In addition, our versatile ultrashort pulse laser offers you unique innovative advantages.
Diversity of technology
Your developers and designers use the know-how of the HAILTEC team and the versatile Technology mix:
- Laser fine cutting
- UKP laser microcutting
- Micro waterjet cutting
- UKP laser ablation
- UKP microstructuring
- Black Marking
- Forming technology (punching, bending, forming)
- 5-axis simultaneous milling
- wire EDM
- Surface grinding
- Surface finishing
- Nano-precise measurement technology
Also interesting
- In-house design department with integrated CAD/CAM systems
- Inspection of your components during production using state-of-the-art measuring technology
- High-end measurement technology from Bruker Alicona
- Assembly with automation solutions for series
- Large material warehouse on site
- ERP system with BDE/MDE
Material variety:
In prototype construction, the quality of your sheet metal parts depends on many factors. In addition to strength, bending radii, and spring properties, the material also plays a key role. Therefore, we source high-quality materials from our suppliers. We also process materials you provide, as well as materials you provide, such as pre-punched strips. One thing is certain: We keep many materials in stock to save you time and money in procurement.
Common materials for samples and prototypes that we have in stock:
Spring steel strips: Spring steel strip, or spring steel, has particularly high strength compared to other steels. The material has a wide range of uses, from the small spring in a clothespin to springs in motor vehicle chassis.
Niro: Stainless steel, abbreviated NiRo or NiRoSta, refers to a group of corrosion and acid-resistant steels.
CopperCopper is a relatively soft and malleable material that also occurs naturally. More about Copper laser cutting of samples and prototypes
CupertinoCopper sheets are available in various alloys and differ, among other things, in their strength. Commonly used copper alloys include CW008A, CW024A, and CW004A.
Titan: The metal titanium impresses with its enormous resistance and low weight.
brassBrass (like bronze) is a copper alloy. Non-magnetic but highly conductive, it is suitable for many applications and industries, such as bent parts in prototype construction.
Alu: Aluminum, or aluminum sheet, is one of the most common metals. It is relatively soft and ductile, which is why it is also used as a thin foil. The light metal aluminum also has good thermal and electrical properties.
Technology diversity:
Probably no other supplier offers you such a diversity of technologies. Like a Lego construction kit, we select the most cost-effective production method for your order. This provides considerable flexibility when manufacturing your prototypes or small series. The combination of our expertise and technology mix enables the fast and cost-effective production of your samples, prototypes, and small series. This has quickly earned us A-list supplier status with numerous clients. These include well-known companies such as ElringKlinger (automotive industry) and B. Braun (medical technology).
For example, we produce initial sheet metal prototypes of your component using a laser. However, once you're ready to go into series production, punching or CNC milling is often more suitable.
These added values await you at HAILTEC
Good reasons for HAILTEC: Speed and expertise
project management
We assess feasibility and cost-effectiveness for you and implement your project from A to Z – imaginatively and reliably. Of course, we also handle surface finishing, such as frame galvanization, for you.
Quality
A modern ERP system, lean and secure processes, ISO certifications and modern measuring technology guarantee you 100% quality.
Lean and fast
Thanks to modern CAD/CAM software, short paths and consistent lean management, we quickly create your solutions, such as prototypes and samples of delicate stamped and bent parts.
Automation
With the help of robotic support and automation, your small series and series are produced quickly and economically.
Technologies for sample prototype construction in profile:
Precision laser cutting is a technology for cutting sheet metal and other materials. The cutting tool is a laser beam, and the cuts are typically very precise. Precision laser cutting is particularly well-suited for the production of prototypes and small series because it is fast and precise and does not require any tools that need to be specially manufactured or replaced.
Micro waterjet cutting is another cutting technology. A fine waterjet typically produces very clean and precise cuts. Micro waterjet cutting is particularly well-suited for temperature-sensitive samples and prototypes, as the waterjet does not heat the material. It is also suitable for samples made of thin materials and for complex geometries.
The forming technique involves mechanically deforming the material. HAILTEC frequently uses this technique to produce delicate sheet metal parts and small bent parts by punching, bending, or pressing them.
Why are precision laser cutting, micro waterjet cutting and forming technology particularly suitable for prototype construction?
Here we take a look at the similarities between the three technologies, which are particularly well suited for the production of sheet metal prototypes and small series.
First, the technologies are typically very precise and allow parts to be manufactured with very exact tolerances. This is especially important because accurate prototypes ensure that the final product meets requirements.
Secondly, these technologies are usually flexible and suitable for prototyping in different shapes and sizes, which is important during the testing phase.
Third, the technologies are also suitable for small-batch production, as they are generally fast and efficient. This is important because prototypes are usually only required in small quantities.
In conclusion, it can be said that the technologies
• Precision laser cutting
• Micro waterjet cutting
• Forming technology
The bottom line is that they enable cost-effective production of sheet metal prototypes and small series.
Discover all technologies at HAILTEC
Industrial prototypes: What matters in development
Definition of prototypes:
Prototype construction (or sample prototyping) and prototype manufacturing are frequently used terms in many sectors and industries. But what exactly is a prototype? The word comes from the ancient Greek "prōtótypon" (we don't speak ancient Greek, but a little smart-ass talk is fun every now and then 😉).
In technical terms, a functional, often simplified model is referred to as a prototype. Depending on its purpose, a prototype can be a precursor to a series or a small series, as is often the case with sheet metal components. In some cases, however, prototypes are also intended as one-off pieces. Since the term "prototype" is relatively generic, a more precise distinction is made on a case-by-case basis between:
- Technical prototypes
- Design prototypes
- Functional prototypes / Functional prototypes
- Geometric prototypes
Definition of small series:
Everyone seems to have a different understanding of the term "small series." Therefore, we'll explain HAILTEC's definition of a small series for potential customers here. It ranges from 2 to 500.000 parts.
For many customers, almost 500.000 parts are already a large series, while other industries that offer consistent mass products can only smile wearily. Therefore, a definition is necessary. A small series is a specific production method that lies between prototype production and series production. Small series are therefore product groups with a limited number of pieces. Trends such as product customization lead to small batch sizes and thus to small series, and this also applies to sheet metal production.
Prototypes small series: Your manufacturer for bent sheet metal parts
The cooperation with HAILTEC is always based on your wishes – this is demonstrated by the following Application example:
Sheet metal prototypes small series: Industries
Whether hydrogen, battery cells, e-mobility, or automotive: As a development partner in sheet metal, we support clients with a unique technology mix, extensive expertise, and a well-connected team. For applications in the following industries, among others:
- Medical Technology
- Automotive
- Engineering
- E-mobility
- electrical industry
- Micro/precision engineering
- Tool and Mold Making
- Aerospace
- Science of measuring and control engineering
- Watch industry
- Model
- Embossing and punching technology
Frequently asked questions about prototypes & series of stamped and bent parts
How does HAILTEC ensure reproducible sheet metal prototypes and small series?
Our processes are consistently lean and aligned with a zero-defect philosophy. These include:
- ERP system with warehouse management
- Traceability & Reproducibility
- Material test certificates
- Trained staff
- Fixed work plans and recipes
- Documentation for every machine and application
- Economical production thanks to robot automation
Does HAILTEC offer a minimum coverage for series production?
If necessary, we will agree a minimum guarantee with you in writing, e.g. that we keep at least 5000 units of your series part in stock and that you can call it off within X days.
How does the collaboration with HAILTEC work?
What makes collaboration so uncomplicated: A contact person At HAILTEC, we take care of all your needs. This simplifies your development process, saves you time, and saves you stress.
We are happy to take over the complete Project management for you – from design to construction, material procurement and toolmaking.
Whether there will be any further short-term changes to implement or technical challenges await: We will find a good solution for you quickly and reliably.
On your behalf we will take over the Manufacturability analysisWe bring our expertise in forming and laser technology to bear on your development.
Technically and scheduling wise we work in close coordination with your team.
Are there tooling costs for samples?
Good to know: At HAILTEC, you can often get prototypes and small series without tooling costs and with short delivery times. That's why customers from Baden-Württemberg's stamping region, the greater Pforzheim area, and the entire DACH region rely on HAILTEC's prototyping service.
From sample to series - this is how it works
Take advantage of synergies and save time, money, and effort: We accompany you from sample production to series production. We cut small quantities quickly and cost-effectively with laser cutting; if your production runs increase, switching to punching technology is a good option.
Your benefits
- A reliable partner for prototypes and series
- Consistent quality and precision
- Economic prices
Is your prototype going into series production? We are also committed to your series production.
Solid arguments for HAILTEC series:
1. Everything under one roof
Development, design, toolmaking, and manufacturing are all under one roof. This eliminates interfaces and saves you time and effort. Upon request, we can also handle the surface finishing of your components.
2. Comprehensive technology park
We use the right technology for every batch size. This production range and
-depth makes you flexible and saves costs.
3. Traceable with test certificate
No matter how small or large your series, batch traceability is included with us. A modern ERP system ensures this.
4. Zero-defect philosophy
You'll receive our high quality standards in writing – for example, in material test certificates and test reports from our measurement laboratory. It goes without saying that we adhere precisely to delivery deadlines.
Why is HAILTEC your reliable partner for prototypes and small series?
HAILTEC is a reliable partner for prototypes and small series production because we have decades of experience in manufacturing precision components. Our engineers and technicians are expert and can assist you in the development of your products. We have modern production facilities and process your orders quickly and reliably.
What is important when manufacturing prototypes?
Prototyping is an important process in product development. Prototypes can help test the functionality, ergonomics, and/or appearance of a product. In many cases, it is important that prototypes are as close as possible to the final version of the product. Therefore, it is important that prototype production is carefully planned and executed.
What is important when producing small series?
Small-batch production is a complex process that requires many different aspects to be considered. First of all, it's important to create a precise plan to ensure all necessary steps are taken into account. Furthermore, it's important to work carefully and avoid mistakes, as any errors can affect the quality of the final products.
Member of networks and associations
HAILTEC - Your certified partner
Our partner in ultrashort pulse laser processing
dmg mori for Llaser systems and software programming | TRUMP CARD for femtosecond laser sources | alicona for nano-precise optical measurement of 3D embossed shapes | Ceratizite for the field of corrosion-resistant hard metals