A Legacy of Engineering Excellence

Foundation of the company GEBO Technic-Engineering in Fürth, Germany

The company’s foundation by Dipl.-Ing. Georg Boguslawski was built on a series of critical projects, including the design and construction of deep drawing and progressive dies.

These early partnerships with industry leaders such as Grundig, ElringKlinger, Siemens, AEG, Triumph-Adler, and others were instrumental in establishing a reputation for precision engineering and high-quality tooling solutions.

Expanding Design Capacities through International Collaboration

To meet growing demand and scale its operations, the company initiated a strategic collaboration with Polish engineers.

This partnership significantly increased the firm’s design and construction capacities, enabling it to efficiently handle a larger volume of projects and reinforce its position as a leading provider of engineering services.

Innovating with Ultrasonic Welding Technology

A key milestone was reached with the construction of the company’s first welding machine using ultrasonic sonotrodes.

This innovative solution was specifically designed for the automotive exterior sector, enabling the precise and efficient joining of bumpers and sensor brackets, further solidifying the firm’s expertise in advanced manufacturing techniques.

Pioneering Flexible Robotic Punching Cells

The company designed and constructed its first robotic cell for the flexible processing of various bumpers in one machine.

This innovative machine was engineered with modularity at its core, allowing it to be easily expanded with new product variants.

Its intelligent design also ensures long-term value, as the foundational structure can be reused for future applications simply by changing out the tables and tools after a production series is complete.

Modular Welding Solutions for the Automotive Sector

The company’s expertise in automation expanded with the design and construction of a modular welding robotic cell for the automotive exterior sector.

This advanced system offers exceptional flexibility, enabling rapid retooling and adaptation for various production needs, which provides a highly efficient and future-proof solution for modern manufacturing challenges.

Pioneering Modular Inspection Gauges

The company began designing and constructing inspection and measuring gauges for various automotive exterior parts, an expertise that has since resulted in the production of several hundred units. The core innovation of this work is a modular design philosophy that replaces a few complex components with multiple simple ones.

This approach offers significant advantages: it eliminates the need for expensive 5-axis milling machines, shortens production times through parallel manufacturing, and reduces costs by utilizing standard parts. Most importantly, the modular design empowers technicians to correct minor deviations on the spot, preventing production delays and rework.

Relocation of Polish Design Office

To support its continued growth and international collaboration, the company’s Polish design office was relocated from Bydgoszcz to Zielonka (Biale Blota). This move strengthens the firm’s operational footprint and enhances its ability to deliver high-quality engineering services to clients.

Developing Backup Stamping Devices for Uninterrupted Production

A key innovation was the development of manual hydraulic backup stamping devices, designed to produce bumpers at series quality even during machine failure. The modular construction allows them to utilize original cutting tools from the main production machines, eliminating the need for additional spare parts inventory.

Operating via a manual hand pump and spring-force reset, these devices enable JIS (Just-In-Sequence) production to continue seamlessly, even in the event of a power outage, as electricity is only required for optional lighting. This low-cost solution, which can also be used for low-volume series production, boasts minimal investment costs due to its simplified mechanical design and safety concept.

Engineering a Landmark Combined Tooling Machine

The company designed its largest and most complex punch-emboss-weld device to date for the Mercedes-Benz Sprinter (Daimler VS30). This single machine was engineered to perform multiple operations on the front bumper, including punching six openings for parking sensors and separate openings for fog lights.

To address the complex geometry of the bumper, the design incorporated a solution where initial pre-centering holes were punched, allowing the stamping units to accurately align and absorb lateral forces. Subsequently, park sensor brackets and fog light holders were joined using ultrasonic sonotrodes.

The firm’s innovative and compact design ultimately allowed them to combine two machines into a single unit. This not only streamlined the process but also significantly reduced manufacturing costs by requiring only one PLC, control cabinet, and set of pneumatic equipment.

Strategic Adaptation: Establishing an In-House 3D Printing Department

In response to supply chain disruptions during the COVID-19 pandemic, the company strategically established a 3D printing department with two FDM printers. Complex parts, such as fixtures and hold-downs, were quickly re-engineered for in-house manufacturing.

This innovation allows for rapid production at the German and Polish locations, ensuring business continuity.

On average, the 3D-printed parts are 70% more cost-effective than comparable milled parts, which significantly reduces production costs and shortens the overall manufacturing time for machines and assembly tables.

Engineering Solutions for a Luxury Yacht Manufacturer

The company’s expertise expanded into the marine industry with its first project for a renowned Polish manufacturer of luxury yachts. The project involved the CAD design of both laminating molds and complex steel welded structures for the assembly and transport of modules for yachts of approximately 30 meters in length, showcasing the firm’s ability to handle large-scale, specialized engineering challenges.

Designing a Complex Automated Assembly Line

The company supported a client in the design of a complex, automated assembly line for the Siemens S7-1200 SM controller. This modular line was composed of multiple stations, requiring deep integration with the client’s existing SAP system.

To meet this unique challenge, the firm demonstrated its high flexibility by performing the design work via remote desktop directly on the client’s PCs. This quick and agile approach ensured a seamless workflow and successful project delivery.

Expanding 3D Printing with TPU for Cost-Effective Automotive Solutions

The company’s 3D printing department expanded its capabilities with new equipment for producing TPU parts using the SLS process. These components feature a soft, rubber-like finish, making them ideal for use in contact areas with painted surfaces in the automotive exterior sector.

This advancement eliminates the need for expensive surface coatings, complex casting molds, or adhesive films. As a result, it leads to significant optimizations in both costs and production times for special machines in the automotive industry.

Handling Gripper Design for Automotive Injection Molding

The company started designing handling grippers for the precise and automated removal of injection-molded parts from tools.

This project showcases the firm’s expertise in creating custom tooling solutions for the automotive exterior sector, optimizing the efficiency of key production processes.