We design components as well as the required tools with state-of-the-art programs. Our highly skilled specialists have a broad wealth of experience in the fields of model making, automotive and mechanical engineering. Amongst others, our design department is excellently acquainted with:

• the development of multipart silicone and PU- casting and injection tools
• cubings and test cubings (interior, exterior) including design concepts made of plastics, aluminium or steel
• all kind of welding structures
• comprehensive solutions for the manufacture of special purpose machinery
• complete prototypes for the automotive industry, for aviation, aerospace and medical engineering

We read and process the following data: Catia V5, Pro/Engineer, FiberSim, TEBIS, AutoCAD, Alias, IGES, VDA und STEP, DXF, DWG

Our long-lasting partnership with KLK allows us to keep the process chain in-house, thus minimising interface problems and conflicts of interests. A comprehensive and single-source solution is to your benefit providing you with a high adherence to schedule as well as budget reliability. We guarantee absolute secrecy and provide data security via Odette file transfer protocols, amongst others.

Process and production engineering contains development, optimisation and the organisation of workshop and machine procedures.
With our production possibilities, we can realise the optimum solutions.

Innovative ideas or extraordinary component requirements sometimes seem to cause irresolvable problems to the production process. With our innovation dynamics we have managed to institutionalise the process and production engineering over the years. On this basis, we are continuously enhancing our processes. The manufacturing of components or the production management seems irresolvable? We are your competent partner to find the right solution and efficiently implement all your requirements.

Our procuction and process management is neither tied to a particular sector or internal infrastructure, nor is it dependent on specific material or processing. That means we offer our services to all sectors with challenging assembly tasks, no matter what kind of processing material is required and in any stage of development.

Due to our wide-ranging competence concerning materials, applications and engineering services as well as our great depth of production and our extensive network, we are able to offer you manufacturing expertise on the highest level, starting from the design up to series production.

Examples:

• Problem: A sandwich panel (CFK/aluminium) for a satellite housing cannot be manufactured. Solution: GERG develops the manufacturing.
• Problem: Serva Transport Systems –prototypes exist, however, without performance specifications and required improvement regarding product performance and production. Solution: GERG develops a series concept and its production.

From the first draft to the final product, a prototype is the benchmark on track. It might equal the target product physically or technically – depending on which parameter e.g. customer response, functionality or technical feasibility is to be tested.

Our long-time experience in the construction of prototypes enables us to implement every step in the process in-house, starting from the idea and going all the way to an individual item ready for serial production. For any kind of requirement we are flexible to choose the right material and the most effective application in order to manufacture a high-end quality product fast and efficiently. That is how we create valuable synergy effects. Every application and every process step is accompanied by the specific specialists and the corresponding infrastructure: from the designer’s first draft, towards project management, to the final control of the class A surfaces.

The combination of engineering know-how, handcraft and the comprehensive manufacturing and process technology distinguish us as a powerful single-source supplier for the industry and technical enthusiasts.

Projekte

We are well-prepared for the individual production in small quantities. Machinery with short changeover and retooling times or automatic assembly allow cost-effective small-series production with highest process reliability. Bar loader-aided turning and palette exchanger-aided milling facilitate serial machining. Casting technologies are generally serial production applications with the major part of cost being generated by the tool making. Hence, cost per unit decline significantly in relation to the batch size. Depending on the component size, various casting machines for different tool sizes are available. Also, the quality control via NC measurement is adjusted to small-series production. Defined checkpoints are processed automatically. Finally, our storage management permits tracking the used materials per batch.

Besides the cost-driven tasks, the company Modell- und Formenbau Blasius GERG GmbH has always been a handcraft business. Since the founding of the company we always have been living the manufactory idea with passion. We provide individual items and small series of highest quality and with a production depth unrivalled in this field.

We are able to create complex geometry in plastics, composites, aluminium, MMC and also in very hard-to-machine materials such as titanium or high-strength steels for applications in aeronautics. Short processing times are guaranteed due to the simultaneous machining of five sides and the use of palette exchangers.

Our machinery in operation is state-of-the-art and features an enormous base accuracy. The latter is ensured by special groundings, high geometry standards in the set-up and climatisation of the production halls.

Extensive raw materials in stock, diverse machinery and short ways within the individual departments reduce the lead time and allow parallel production processes. Close quality control allows efficient check measurements in line with the production process.

For more than 25 years we cooperate with Tebis AG in a development partnership and work with our own postprocessors. Our highly experienced and skilled specialists evolve sophisticated milling strategies as these bear high potential regarding feasibility and cost. In order to ensure improvement we implement milling tests on a regular basis.

One of our specialities in the milling department is the machining of MMC, a particularly tough silicious aluminium alloy used in motorsports, and the machining of titanium with specifically designed machinery.

Unique in this sector is our capacity to offer the complete process chain from CAM to CAD, milling, lining, finishing and quality assurance from a single source.

The clever combination of turning and milling with other manufacturing technologies, e.g. eroding, curbs our production costs and boosts the manageable complexity of the components.

We process all metals and plastics as well as fibre-reinforced materials. Our core competence is the precise machining of high-strength materials. Therefore we have created our own machinery park containing particularly stiff and low-vibration equipment. Our specialists with decade-long experience develop strategies which make the crucial difference when it comes to tight geometry or critical raw materials such as titanium. Another characteristic is that every machine operator is at the same time the programmer of the corresponding workpiece. Hence, another interface is skipped for the benefit of reliability and quality.

We achieve the maximum of accuracy through air-conditioned production halls, high-quality tools and process-related quality checking with dimensional measurement systems such as roughness testers and profilometers. In case of urgent orders our clients benefit from our excellently equipped inventory containing even high-strength steels for aeronautic applications which often are only available with considerable difficulties.

Selective Laser Melting (SLM) is an additive manufacturing process often referred to as 3D printing. Currently we can fabricate parts up to a volume of 800 x 400 x 500 mm, that cannot be realised through classic manufacturing processes. In the process SLM layer by layer with a thickness from 25 to 60 µm is melted by a laser with up to 1000 W and is solidied close to contour. We process aluminium (AlSi10Mg), high-strenth tooling steel (1.2709) and titanium (Ti6Al4V).
The almost complete freedom of design allows the production of highly optimised load-specific components. It´s economically remarkable that production costs do not depend on part complexity.

In combination with our other manufacturing technologies, we offer customized solutions. Examples given:

• Complex SLM-part are post processed on high-precision milling- and turning machines, assembled to bigger components and finished for delivery.
• A SLM-part in bionic design is integrated in a CFRP structure. The result is a high performance hybrid structure
• The whole value-creation chain: description and definition of the component >> design >> topological optimisation >> FE simulation >> design adaptations >> manufacturing by SLM technology >> post processes (milling, welding, bonding, surface treatment …) >> quality assurance

A speciality of our in-house laser welding technique is the possibility to incorporate filler in order to stabilise structures. Almost all fusion-weldable materials are suitable for this application. The WIG welding technique with its wide range of usable raw materials, the good accessibility and the perfect weld pool control makes an ideal complement to laser welding. This combination allows us to build complex high-performance modules with up to 2 m³, for example attachable frames or supsension components for motorsport.

For example, we create welding constructions out of high-strength steel (1.7734), aluminium (EN AW-6082) or titanium (Ti6Al4V). Amongst others we also build complex hollow structures consisting of many single sheets (tmax = 3 mm). High process reliability and repeat accuracy with minimal thermal distortion are crucial when it comes to the reliable realisation of components with extremely high mechanical load capacity.

Our know-how allows us to join aluminium sheets (6000) susceptible to solidification cracking. We generate mechanical strength properties within the weld and the heat affected zone of up to 75-80% of the base material for the alloy EN AW-6082; completely without subsequent thermal treatment.

With wire EDM, a wire cuts through a workpiece. Due to an electric process, material is released from the workpiece close to the wire. This allows a very high degree of accuracy with the omission of cutting pressure and a cutting volume at molecular scales.

The wire has a thickness of 0.25 mm and is CNC-control guided through the component part. This procedure requires a lot of experience – therefore we have appropriate specialists. The combination of in-house turning, milling and welding techniques together with the eroding technology enables us to offer you a comprehensive treatment of all metallic materials.

Infrastructure:

• FOBA G5
• ACSYS Piranha

Fibre mats impregnated with resin are used in the prepreg treatment. In the autoclave these workpieces are then cured at high temperatures and under pressure. The resulting components are extremely high-performing due to the high fibre volume content.

Depending on demand and intended purpose we chose the adequate technology: Sandwich constructions, the integration of inserts, different lost core or blown core technologies in order to generate hollow bodies and undercuts.

Our expertise in the area of prepreg technology with all its upstream and downstream processes is broad and profound. In combination with our excellent infrastructure, especially for motorsports applications, we are your powerful provider for complete assembly groups.

VPL is an enhanced version of the CFRP injection technique (RTM) using lost cores. That is how we reach a level of geometric freedom, which was formerly only possible via casting or rapid prototyping technology. VPL is applicable for parts with complex contours or undercuts. The surface quality of our VPL laminates is particularly sophisticated, usable up to temperatures of 220 degree Celsius. Of course they retain their extraordinary accuracy and properties. Possible component sizes start at 1 g and go to a maximum volume of 1200 x 800 x 800 mm. Moreover, compared to other composite processing techniques, complex pieces can be manufactured within shorter periods.

The leading competitors of endurance racing in the past years, for example, are equipped with our ultra-light air boxes in VPL design.

One of two available braiding machines in Germany with 144 carriers is located at our site. This machine enables us to produce customised hollow components and C-profiles made from CFRP. The robot-aided core feeding system allows reproducible braiding around curved and concave structures with filler threads on the inside and outside surface. The machine allows modification for different circumferences starting from 100 mm as the number of threads is variable. Due to large-sized centre opening we are able to braid structures with a length of up to 7 m. On demand it is possible to produce a variety of cross-sectional geometries and surfaces over the entire length of a component.

Our main technologies include blow - and foam cores which in combination with the braiding create synergy effects. Being our client you particularly benefit from compatible single components and short delivery times.

Due to the major part of manual steps in wet lamination processes, it is especially important to provide an in-depth quality controlling by skilled and regularly trained staff. Production of wet laminated components can be supplied in GRP, CFRP or AFRP depending on their purpose of use. For enhanced laminate quality all parts also can be produced by using vacuum technology. The curing process for huge workpieces takes place in a dedicated tempering hall with a maximum temperature of up to 90° Celsius. Small components are cured in furnaces up to a maximum of 250° Celsius.

Our employees handle all kinds of materials and, besides special attention for the details, always have the big picture in mind. The passion of our model making team is reflected in exact slit and panel alignement as well as the clean cut lines.

The perfect synergy of ultra-modern machines and manual know-how is what creates inspiring design models which fuel enthusiasm.

In the development phase, CAD data in the data control model is presented at a reality scale of 1:1 for the very first time. This is an important step toward series maturity as it makes the designer´s and engineer´s work visible. Subsequent modifications can be implemented via reverse engineering in the original CAD model.

Years of experience, our high quality awareness and the high flexibility of our staff stand for excellent data control models. Our expertise in upstream and downstream processes guarantees economic advantages.

The cubing simulates the target state of a component of a body shell framework and is used as a reference model in order to test all connected serial components. As all built-in units are adjusted to a zero measurement, a precise fault analysis in all phases of development is possible.

All original interior and exterior vehicle parts are tested in terms of fit and function with cubing technology. Cubing allows to prove the function of flaps, doors, illumination or gaskets in an early stage. Depending on the intended application, we laminate or cast the testing equipment or we mill it from aluminium. If needed, also other manufacturing techniques can be deployed. Our cubings are set up in a climatised room on a measuring slab to guarantee maximum accuracy.

Infrastructure: Measuring slab with a measurement range of 11000 x 2800 x 2600 mm

The aim of gauge building is to precisely image and control every component and thus enable the possibility of solid evaluation, documentation and visualisation methods. For every process step up to the smallest detail we produce gauges. Therefore we cooperate closely with our partners from the automotive and aviation industry. Like this the testing equipment we provide is at the highest possible precision level which is required for maximum process safety.

With the latest innovative polyjet printing systems we are able to generate finest geometrics and surfaces. Via stereolithography we produce generative parts with photopolymersiation resins. With this we can realise even complex geometrics such as undercuts and hollows. By means of selective laser sintering we generatively process not only plastics but also metal and ceramic materials. Thus, basic material in powder form is converted into workpieces which cannot be produced in conventional mechanical processes. We finish almost all 3D surfaces with diverse textures by using water transfer printing.

For machining we use our precise high speed milling machines. This allows us to realise also small and very elaborate components with highest finishing quality and accuracy.

Among others, luminaire and light technology is our speciality. We provide highly precise first samples and prototypes and also small series. Being the illumination technology of the future, fibre optics are for example used in vehicle construction, interior design or as design applications.

The direct connection to our in-house range of services generates synergy effects of all kinds; from design to construction and programming to the casting of the component in aluminium out of the rapid prototyping mould without further tooling costs.

Our expertise is ground-breaking and outperforms the industry standards by far. We design our own machinery and develop new techniques. We deliver single-, two- and three-component parts in all types of shore hardness. If demanded, castings are reinforced with metal of CFRP. Our portfolio also comprises glass-rubber composites for example glazing with injected sealing. With our know-how we design components more effective or even spare out components, as one part takes over the function of multiple others. All-of-a-piece-like.

Low pressure vacuum casting means almost unlimited scope for design. It realises components that are not producible with other methods or if so, only with great efforts. In combination with rapid prototyping, functional parts are generated within a short time.

We realise components within a weight range of grams up to 5 kg for a single unit and with a maximum edge length of 600 mm. We process all castable aluminium alloys. The conditions similar to die casting make our production procedure predestined for serial development or pre-series production. Our system works with a steered moulding process, guaranteeing constant quality. As the moulds are not hot but cold, the resulting part is of finer grain structure. Subsequent heat treatment provides defined mechanical strength properties. With a design optimized for precision casting we can produce weight critical parts with a minimal wall thickness of 0.8 mm.

Another great advantage of our precision casting technique is its flexibility. On the one hand we reach excellent quality regarding size accuracy and surfaces by milled models; on the other hand we optionally integrate 3D printing components for small units without much additional tooling costs. This method is not only useful for prototypes or initial samples but also for small and medium-sized batches up to 500 units.

For the setup of complete vehicles or similar structures we have duplex measuring machinery in different sizes and a CNC portal coordinate measuring machine at ground level. All equipment is operated by skilled staff with the relevant methodological know-how. A Faro arm is available for measuring mobile applications or angled objects such as vehicle interiors. It is additionally equipped with a 3D scanner to measure surfaces efficiently. Not-easy-to-access sections we are able to check by means of endoscopy; surfaces we can examine with an optical microscope equipped with a camera system.

Highest quality demands extensive material testing. This is crucial in both the development stage and during quality assurance. We do not involve external providers which is how we can cut costs and increase flexibility. Your advantages - besides highest quality standards - are prompt availability and favourable prices.

Standard methods we apply are: testing of CFRP monocoques at the torsion testing facility; process validation of welding technologies during tensile testing; controlling of heat treatment processes during hardness testing.