The globally active HEYCO Group on the way to climate neutrality

Over 1,250 experienced HEYCO employees in Remscheid, Tittling in Bavaria, the Czech Republic, Ireland and the USA work together with customers on many innovative projects, including electromobility, one of the megatrends in the automotive industry.

Founded in 1937 and now managed by the third generation of the Heynen family of entrepreneurs, the HEYCO Group meets market requirements as an innovative company with the typical characteristics of a medium-sized enterprise: sustainable, down-to-earth, reliable

Plastic cell frame for holding the round cell batteries

“We produce components that are indispensable for the mobility transition to electromobility,” says Markus Heynen, Managing Partner of the HEYCO Group. These can be very specifically geared towards electromobility, such as key components for electric batteries. However, they can also be used universally in all vehicles with other modern drive concepts. “A special component is the so-called cell frame, whose components are manufactured in the plants in Remscheid and Tittling,” Heynen continues. The cell frame is the central component in the battery box and is used to hold and cool the round cells. The high level of complexity is due to a structure with several materials in 2-component injection molding with simultaneous overmolding of metal inserts as a special alloy.

In addition to these cell frames, HEYCOS’ core competencies include fire protection and crash safety. „Die größte Gefahr für einen Fahrzeugbrand bei einem Elektrofahrzeug geht von Schäden durch Deformation nach einem Unfallgeschehen aus“, erklärt Jörn Krüger, Geschäftsführer Metall. This can lead to direct deformation of the battery unit as a trigger for an uncontrolled fire or to the battery system being torn out of its anchoring points on the bodywork. The HEYCO Group provides solutions for both cases. “HEYCO manufactures forged and finished components such as structural elements or edge reinforcements at its site in Tittling,” Krüger explains. The high-strength and stable construction components prevent the battery box from deforming in the event of a crash and damaging the battery cells. They also hold the battery system firmly in place by compensating for the impact energy without tearing out of the anchorage.

However, in the unlikely event of an uncontrolled battery fire, known as a “thermal runaway”, external fire protection must be used to ensure that the occupants can leave the vehicle safely. For this purpose, protective elements made of special fire retardants and applied fire protection materials are positioned over the relevant parts of the battery system. In addition to a correspondingly high dielectric strength, these have above all a high heat resistance over a defined period of time. “Thanks to the collaboration between HEYCO and STEINMANN development experts, it was also possible to develop and test innovative hybrid components,” report Dirk Schibisch, Managing Director of Plastics, and Nico Stratemeyer, Managing Director of CARL STEINMANN Kunststoffverarbeitung GmbH, in unison. These results open up a wide range of solutions for lightweight and form-fitting plastic covers that are also equipped with fire protection material. Such components are also more cost-effective than alternative aluminum panels.

The HEYCO Group, more precisely the company CARL STEINMANN Kunststoffverarbeitung GmbH, is already supplying appropriate fire protection materials for high-voltage battery systems in series production. The HEYCO subsidiary CARL STEINMANN has taken over the Czech supplier C connect s.r.o. with retroactive effect from the beginning of 2023. STEINMANN is thus significantly expanding its own vertical range of manufacture, particularly for safety-relevant fire protection components and the necessary expertise.

(from left to right) Nico Stratemeyer, Pavel Vanek/Managing Shareholder of C connect s.r.o. and Markus Heynen after signing the contract in Prague/CZ. Partner of C connect s.r.o. and Markus Heynen after signing the contract in Prague/CZ

“I am delighted to be able to continue the business with the experienced team at the very suitable location,” summarizes Nico Stratemeyer. The mechanical processing of plastics, foams and films as well as screen printing and the assembly of smaller components are among the core competencies of the company, which is located in the immediate vicinity of Prague. For example, thermal insulation mats, seals, plastic parts and protective, design and sealing films are produced there. Innovation potential is seen, among other things, in products relating to the accident protection of modern vehicle battery systems.

CARL STEINMANN Kunststoffverarbeitung GmbH was incorporated into the HEYCO Group and integrated into the Remscheid headquarters at Birgden III under the leadership of the senior partner, Mr Ernst Peter Heynen. The success of this subsidiary over the past decades has now made it possible to add a second production site.

“This acquisition also demonstrates HEYCO’s ability to remain consistent in the face of change. We have to adapt very flexibly to the requirements of demanding customers in the international automotive industry, who are also in a state of flux,” states Markus Heynen. Electromobility and automated driving have been extremely accelerated following the recent crises. The combustion engine would run out just as quickly. “For us, this means that old business areas may very quickly become a thing of the past. Flexibility is the order of the day in the near future if we want to still be present on the market in ten years’ time. And that’s what we want,” emphasises Markus Heynen.

This change is also taking place on the labour market. More and more women are aspiring to “typically male professions”. And very successfully, at least at HEYCO. “We can only train the next generation ourselves,” everyone at HEYCO knows.

This commitment has been particularly successful not only at the Tittling training centre, where our trainees are regularly awarded the Bavarian State Prize for Best Performance, but most recently also at the Remscheid site. The four trainees Saskia Passen, Christina Theodorou, Rumeysa Vergi and Saskia Schell won the Energy Scouts 2023 competition organised by the Bergische IHK under the guidance of trainer Markus Hoffmann. They mainly focussed on determining compressed air losses in the pipe networks of the production areas and how to avoid them. These energy-saving concepts are now to be implemented in other HEYCO plants.

(from left to right) Saskia Passen, Markus Hoffmann/trainer, Christina Theodorou, Rumeysa Vergi and Stefan Scholz/production manager at the award ceremony (not in the picture: Saskia Schell)

In addition to its original business with hand tools, the HEYCO Group is now primarily known as a supplier of plastic and forged parts for the automotive industry. HEYCO is also valued by customers as a competent development partner for the module and system business.

The HEYCO Group is a dynamically growing company with 7 locations in Germany, Europe and the USA. Over 1,250 employees develop and manufacture technically and qualitatively sophisticated components.