Assembly manufacturing for prototypes and small series made of metal and plastic
Assembly manufacturing combines various manufacturing and assembly steps into a functional unit. Instead of sourcing numerous individual components from different suppliers, all-forming provides you with a ready-to-assemble solution from a single source.
From individual part production and mechanical processing to final assembly, we centrally coordinate all process steps. This reduces interfaces, simplifies procurement and shortens project lead times.
Companies particularly benefit from centralized production control and a high degree of flexibility for technical changes in prototype manufacturing and small-series production.
Service areas: Sheet metal assemblies, welded assemblies, hybrid assemblies and injection-molded assemblies
Additional services: Laser engraving, DMC codes, serial numbers, component marking and traceability
Your partner for assembly manufacturing and complete assembly
all-forming combines various manufacturing technologies to create economical and technically sophisticated complete solutions.
By combining laser cutting, sheet metal processing, CNC machining, welding, forming and assembly, finished assemblies are produced with short delivery times and high quality.
Your benefits:
- Everything from a single source
from the individual part to the complete assembly - Fewer interfaces
less coordination and consultation effort - Greater process reliability
one central contact for the entire project - Flexible adjustments
rapid implementation of changes during the project phase - High vertical integration
numerous manufacturing steps carried out in-house - In-house toolmaking
- Personal support
from the inquiry to the finished component
Renowned industrial companies trust our assemblies
Selected projects & assemblies
Our projects demonstrate the versatility of assembly manufacturing. From precision sheet metal assemblies and complex injection-molded assemblies to welded assemblies, we manufacture assemblies for a wide range of industrial applications.
- On-time implementation
- Everything from a single source
- Flexible quantities
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Connector manufactured by injection molding
Connector with inserted connector contacts, stamped grids, bushings and threaded studs, securely fixed in the injection-molding process using insert technology. Ideal for power electronics, e-mobility and industrial applications requiring high contact reliability and precise electrical connections.
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Hybrid assembly (metal & plastic)
Functional assembly made of metal and plastic components – combines sheet metal processing, resistance welding and injection molding for complex technical applications.
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Module frame manufactured by vacuum casting
Module frame manufactured by vacuum casting with 50 press-fit pins, several busbars and bushings. The free areas are designed for subsequent installation of printed circuit boards by the customer – ideal for power electronics, control units and hybrid electronic modules.
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Potted busbar holder
Busbar holder manufactured by injection molding, combined with multi-part busbars that are permanently joined by laser welding. The component is then completely sealed by potting using injection molding. Ideal for power electronics, e-mobility and demanding industrial applications requiring high electrical safety and protection against environmental influences.
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Laser-welded busbar assembly
Busbar made of 3 mm copper, supplemented by a 0.3 mm-thin busbar using laser welding. Ideal for power electronics, battery applications and electrical connections with optimum current conductivity and a precise contact zone.
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Hot-staked injection-molded assembly
Complex injection-molded assembly with several busbars fixed to the plastic by hot staking. Ideal for power electronics, e-mobility and industrial applications requiring reliable electrical contacting and high process stability.
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Laser-welded rotor/stator pack
Precisely manufactured rotor/stator pack made of stacked individual electrical steel laminations, permanently joined by laser welding. Ideal for electric motors, e-mobility and drive technology requiring high dimensional accuracy, low power losses and stable stacking.
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Sheet metal bracket with weld nuts
Precision sheet metal bracket manufactured by laser cutting, bending and forming, with weld nuts for assembly – ideal for electronic housings, covers and technical components.
Additional manufacturing processes at all-forming – everything from a single source
In addition to assembly manufacturing, all-forming offers a comprehensive range of sheet metal processing, laser cutting 2D/3D and CNC manufacturing.
Frequently asked questions about assembly manufacturing at all-forming (FAQ)
What is meant by assembly manufacturing?
Assembly manufacturing is the production and assembly of several individual parts into a functional unit. Metallic, mechanical and plastic-based components are combined to create a functional assembly.
What advantages does complete manufacturing offer for assemblies?
Complete manufacturing reduces interfaces between suppliers and lowers the error rate. It enables shorter development times, greater process reliability and better cost control through end-to-end manufacturing from a single source.
Which assemblies does all-forming manufacture?
all-forming manufactures welded assemblies, injection-molded assemblies, sheet metal assemblies as well as hybrid assemblies made of metal and plastic. These are individually produced for industry, e-mobility, mechanical engineering and medical technology.
Which welding processes are used for assemblies?
Depending on the application, laser welding (main process), MIG, MAG and TIG welding are used. Laser welding is preferred for precise, low-distortion and visually high-quality welded assemblies.
Which inserts can be integrated into injection-molded parts?
Busbars, connector contacts, stamped grids, press-fit pins, bushings and studs can be integrated during injection molding. These are permanently fixed in the plastic (insert molding) and form functional assemblies.
What is press-fit technology for sheet metal assemblies?
Press-fit technology is a process in which studs, nuts or threaded inserts are mechanically pressed into sheet metal parts. This creates stable, load-bearing and assembly-ready connections without additional screwing.
Can assemblies be marked?
Yes, assemblies can be permanently marked by laser engraving. Logos, part numbers, serial numbers, QR codes or DMC codes can be applied for traceability and industrial identification.
How quickly can assemblies be delivered?
Delivery time depends on complexity and scope. Thanks to automated processes and in-house manufacturing, delivery times of just a few weeks are possible, including series call-offs and recurring production.
How can parts be ordered from all-forming, and what does the process involve?
The ordering process at all-forming is simple and efficient – with personal support from the very beginning:
- You send us your CAD data (e.g. STEP, DXF) or a technical drawing with all specific requirements (material, coating, quantity).
- Within a very short time, you will receive a non-binding quote from your personal contact.
- After placing your order, you will receive an order confirmation containing all relevant details.
- From this point onward, all-forming takes over the entire manufacturing process – from planning through on-time delivery.
