Complex forged components
The whole is more than the sum of its parts – according to this motto, traditional hot forming at HEYCO has evolved over time into the production of complex assemblies, with further value-adding processing steps downstream of the forming process.
HEYCO continuously invests in modern, largely fully automated CNC machining centers for machining, which, in conjunction with the heat and surface treatment processes, form the basis for sophisticated and finished components. Mechanically machined parts with tolerances in the hundredths of a millimeter range, fully automated and with integrated component testing secure HEYCO’s future not only as an automotive supplier in Germany and guarantee customers the fulfillment of the highest component-specific requirements.
Are you looking for a development partner with implementation experience and prefabrication expertise?
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HEYCO production systems
Hot forming and CNC machining for small and large series production
With high-performance presses with a pressing force of 450-3,150 tons and hammers with an impact energy of 20-63 kJ, we manufacture high-precision forgings from 200g to 16kg.
We develop complete solutions right through to the finished end product.
We offer customer proximity from the initial idea to the SOP. Our material and process specialists guarantee forging and machining expertise.
Customized project teams guarantee implementation.
As your development partner, we work with state-of-the-art development platforms and are able to adopt all common formats, develop them further and test them using material flow simulation.
The fast and flexible implementation using CAD and our own toolmaking allows us to be close to series production right from the prototype phase.
The main advantages of hot forming are
We manufacture:
Flanges for powertrain, exhaust systems and drive systems
Forged from heat-resistant and stainless steels, HEYCO flanges for exhaust systems or catalytic converters are very good examples of HEYCO’s performance. After forming, the components are partially machined and tested on fully automated CNC machines.
Cylinder flanges
Inlet/outlet ring flanges
Ring flanges
Finished weight from 100 – 1,000g
Inlet/outlet two-hole/three-hole flanges
Finished weight from 200 – 1,500g
Chassis components
HEYCO develops the workpiece geometry suitable for forging together with the customer in simultaneous engineering and forges near-net-shape chassis components in Tittling, Bavaria. On state-of-the-art machining centers, these weight-optimized workpieces are machined ready for installation at the customer’s request, resulting in an economically attractive, cost-efficient component.
Control arm
Steering lever
Wheel carrier
Track lever
Engine and transmission parts
Both diesel and gasoline engines will continue to play a significant role in engine and transmission production as the most efficient forms of propulsion until the technology is fully converted to alternative forms of energy. HEYCO is already working on further evolutionary stages.
The complex common rails must have high fatigue strength values and still be space-saving and weight-optimized. These requirements are translated into production-ready common rails in the HEYCO forge. Forged components with optimum fiber flow are also the solution to the various requirements in this application.
Gasoline injection:
Common rail 3-cylinder
Common rail 3-cylinder
Common rail 4-cylinder
Clamping strips/clamping brackets:
Motor clamping bracket
Motor terminal strip
Motor terminal strip
Drive parts:
Vibration absorber
Drive bevel gear
Ring gear
2-mass flywheel
Structural components and fastening elements
Together with the customer, HEYCO develops forged structural components and fastening elements that both meet high strength requirements and are weight-reduced. These components withstand the strongest stresses caused by forces, vibrations and oscillations in high-performance machines better than welded sheet metal constructions. In addition, the sometimes very high cost of quality assurance for the welded joints of a sheet metal part is eliminated. In the case of visible components such as motorcycle frames, particular emphasis is also placed on appearance.
Fuel line connection housing
Holder exhaust gas components
Inlay
Hot end holder
Motorcycle frame component
Motorcycle frame component
Convertible folding roof systems
Convertibles have been an integral part of the automotive scene for decades. As a result, the convertible top technology has been refined further and further to ensure unrestricted driving pleasure. The kinematics in convertible top systems are very varied and often intricate.
In addition to these elements forged by HEYCO, a large number of other components are required to ensure that the soft top can be opened and closed perfectly. Complex assembly groups made of plastic parts, elastic bands, heavy-duty cords, eyelets and springs are used to ensure that the soft top can be folded down and closed again without creasing.
CARL STEINMANN Kunststoffverarbeitung GmbH, as part of the HEYCO Group, has gained a great deal of experience in solving problems for customers and in the manufacture of such components, so that today not only forged HEYCO components but also complex STEINMANN assembly groups are used in many convertibles.
Tension rod
Carrier plate
Main pillar insert
Bracket backlight
Towbars
As a competent supplier of forged trailer coupling systems, we manufacture series of raw parts through to ready-to-install machined solutions on fully automated machining systems, depending on customer requirements.
Housing
Housing (coated)
Trailer coupling – ball neck
Components for agriculture and mechanical engineering
As a competent partner, we are a long-standing supplier, particularly of safety-relevant components for commercial vehicles and special agricultural vehicles such as tractors or harvesters, as well as wear parts.
Thanks to our in-house toolmaking department and our flexibility for small and medium-sized production runs, we are ideally positioned in the area of special vehicle construction in particular.
Rail vehicles are an important means of transportation and are shaping the infrastructure of the 21st century. The expansion of high-speed transportation networks enables fast and secure connections between different metropolitan areas and is becoming increasingly important – especially in Asia.
HEYCO’s complex components are also used here.
Extension arm for disc harrows
Mounting plate boom
Eccentric shaft
Hydraulic component on the boom
Components for electric motors and battery box systems
The greatest risk of a vehicle fire in an electric vehicle comes from a crash. As a partner from the very beginning, HEYCO manufactures structural elements that counteract possible damage to the battery box.