Bulk metal forming

Expertise of forming in powertrain applications

Our main business unit is automotive engineering. We use the model of the “car of the future” which is characterized by economical use of resources and by lowest environmental pollution possible regarding fuel consumption and pollutant emissions during operation. Significant trends of development include electric mobility and more economical and sustainable high-performance combustion engines. For this purpose we develop solutions – comprising transmission and powertrain components as well as components for engine, chassis and steering. Our core competence consists in developing processes for manufacturing solid and hollow shafts, gears, structural components and chassis components. Fraunhofer IWU can realize the following technologies: forging, cross rolling, axial closed die rolling, axial forming, roll forming, extrusion, spin extrusion and rotary swaging.

Further business units consist in power engineering, systems engineering, aerospace industry and medical engineering. 

  • Ultra-short process chains based on forming technology
  • Components with optimized functions and mass
  • Reduced process times
  • Avoiding material loss
  • Increase of material efficiency

Development of process chains

  • Market analysis
  • Investigation of process chains
  • Process optimization
  • Cost-benefit calculation
  • Development of manufacturing concepts
  • Planning and technological development of processes, tools and machines

Development and evaluation of forming strategies

  • Market analysis
  • Feasibility studies
  • Technology development
  • Development of characteristic process values and optimal forming strategies
  • Benchmarking
  • Numerical simulation
  • Manufacturing of prototypes

Machine technology

  • Clutch-controlled screw press SPKA2000
  • Axial closed die rolling machine AGW80/250
  • Flat tool holder cross rolling machine FBQ100/1600
  • Round tool holder cross rolling machine RBQ1000
  • Spin extrusion machine BDM2000
  • Precision rotary swaging machine HA 100-1 SUE LH-NC
  • Axial forming machine Aximus V02
  • Several hydraulic presses with press forces ranging from 50 kN to 6,000 kN
  • Two hydroforming presses (4,000 bar; press force: 15,000/50,000 kN)
  • Two-rolls profile rolling machine PWZ Spezial, Rollex XL-HP and PR15 HP
  • Three-rolls profile rolling machine 3PRD


  • CAD systems ProEngineer, CATIA, Inventor, among others
  • Process simulation Forge, Simufact, LS- DYNA, AUTOFORM, PAM-STAMP, Deform, among others
  • Finite element software ANSYS
  • I-DEAS

Testing technology

  • Precision measuring machine PRISMO7S-ACC (ZEISS)
  • Various devices for measuring optical roughness and profiles
  • Confocal microscope, ITO Stuttgart University
  • White light interferometer, ITO Stuttgart University
  • MikroCAD, GFM Teltow
  • Vcheck, GFM Teltow
  • Scanning electron microscope, LEO Oberkochen; stereomicroscope
  • EDX-System, Oxford Instruments
  • Optical measuring station UBM
  • Contact measuring devices for roughness and profiles, HOMMEL and Mitutoyo
  • Form measuring instrument F2002, HOMMEL
  • Ultrasonic wall thickness gauges