Formfact
02 · Services

Engineering to manufacturing.
Without losses at the interfaces.

We cover the entire value chain of modern special machinery construction. Bookable module by module or as a turnkey overall project.

  • 01

    Design &
    engineering

    • SolidWorks
    • E-Plan
    • FEA analysis

    The birth of every product. Our engineers develop mechanical concepts, design complex circuit geometries and write the hardware-related software. Because we work closely with our own workshop, we design for manufacturing right from the start.

    • 3D CAD modelling & kinematics
    • Design of drive & fluid systems
    • Circuit diagrams & control cabinet layout
    • Risk assessments in line with CE directives
  • 02

    Prototyping &
    validation

    • Rapid prototyping
    • Test rig
    • 3D printing

    All theory is grey — what counts is the test rig. We build functional models and alpha prototypes at speed. We test critical mechanisms separately in order to eliminate development risks early and to validate tolerance chains both mathematically and in practice.

    • Fast supply of milled and turned parts
    • Build-up of functional & ergonomic models
    • Sensor & actuator validation
    • Service life and load tests
  • 03

    Parts manufacturing &
    assemblies

    • CNC milling
    • Sheet metal bending
    • Assembly of modules

    Our in-house mechanical production is the heart of our precision. With state-of-the-art 5-axis machining centres and a well-practised team, we manufacture highly complex components from aluminium, stainless steel and high-performance plastics. We assemble mechanical, pneumatic and electrical components into ready-to-install system modules.

    • 5-axis simultaneous milling (HSC)
    • Precision turning with driven tools
    • Cleanroom-compliant pre- and final assembly
    • 100% quality control (3D metrology)
  • 04

    Turnkey
    systems

    • Special machinery
    • Automation
    • CE label

    From the specification sheet to turnkey handover in your production. We act as general contractor for complex automation cells, assembly lines and test systems. Every system only leaves our plant after a successful Factory Acceptance Test (FAT) under realistic conditions.

    • Linked assembly systems & rotary indexing machines
    • Robot integration (pick-and-place, handling)
    • Camera-based inspection & measuring cells
    • Turnkey delivery including documentation
  • 05

    Retrofit &
    lifecycle service

    • Retrofit
    • Maintenance
    • Remote support

    A product's life does not end with delivery. We support your systems throughout their entire lifecycle. Alongside planned maintenance and a fast spare parts service, we modernise existing legacy systems (retrofit) — for shorter cycle times, modern controls and new safety standards.

    • Control upgrades (S7, Beckhoff, etc.)
    • Mechanical overhaul & wear protection
    • Teleservice & fast on-site support
    • Safety upgrades to current standards
+++

Bits & Pieces

  • Partial scope
  • Service
  • Small job

No job too small, no challenge too big: we tackle partial scopes with the same passion and care as full projects. What every task and every solution have in common? They are simply us.

  • Control upgrades (S7, Beckhoff, etc.)
  • Mechanical overhaul
  • Teleservice & rapid on-site response
  • Safety retrofits to current standards

Five steps to the finished system.

  1. Step 01

    Analysis

    Joint clarification of requirements, feasibility study and definition of the specification sheet.

  2. Step 02

    Concept

    Development of solution approaches, rough 3D layouts and cost-effectiveness calculation.

  3. Step 03

    Detail

    Complete mechanical & electrical design, software architecture.

  4. Step 04

    Build

    In-house parts manufacturing, control cabinet construction, assembly and internal pre-commissioning (FAT).

  5. Step 05

    Operation

    Delivery, final assembly at your site, final commissioning (SAT) and staff training.

Formfact Werkstatt
Formfact · Manufacturing

Figures that speak for themselves.

85 % In-house production

We mill and turn almost all mechanical precision parts ourselves.

5 axes CNC technology

Simultaneous machining for highly complex geometries and the tightest tolerances.

100 % CE compliant | ISO 9001

Every system we build leaves the house with complete documentation. ISO9001

< 4 weeks Rush sample service

We realise simple functional assemblies within the shortest possible time.