Sample & Prototype Manufacturing

Ideas become tangible in Sample and Prototype Manufacturing. Our employees develop and manufacture interior and exterior parts, tools and aids for body construction, model gauges for quality assurance, and driveable and testable prototypes of the highest precision. Economical realization of all projects is our maxim. We view single-minded project management as the basis for accomplishing demanding tasks. With our know-how, which extends over the entire development cycle from the first data record to the ready-to-drive prototype, we create the foundation for the complete vehicle capability of Semcon.

In the component sector, we work with steel, aluminium and magnesium and different joining techniques such as clinching, bonding, riveting and spot-welding.

Assembly body shells for prototypes and zero series vehicles are produced using sophisticated medium-frequency welding technology. The tools are in some cases manufactured with the aid of advanced five-axle milling technique. As an example for the stretched version of the Mercedes-Benz A-Class, developed by Semcon for the customer, for the Mercedes CLS and the Bentley Azure we made sheet metal and plastic tools for the interior and exterior parts. In the fields of mechanics/kinematics, body construction, model making and equipment design, we employ forward-looking CNC technologies; we create everything from comprehensive data control models to cubings in aluminium. In addition, we make bolted and welded cages for racing, testing and production vehicles – for Porsche Motorsport among others.

The structure of the Sample and Prototype Manufacturing business area, with its competence center in Bad Friedrichshall and local centers at all other locations of Semcon, guarantees the consistent concentration of our know-how and our resources as well as a local presence for the customer. The customer has competent people to talk to at every location, along with suitable shop areas. The cross-regional collaboration of our teams is as natural to us as the use of trend-setting technologies and software tools.