Four weeks to shortlisting, 16 months to series production
Typically, the bidding process in the automotive supply industry takes six to twelve months. At Handtmann, it took only four weeks from the initial inquiry to shortlisting. The company then immediately began plant design, procurement, and assembly of the production line; after 16 months, sample testing and process acceptance were completed. “This project demonstrates what is possible when experienced partners in a region work together in a spirit of trust. We have proven that industrialization of this complexity and speed does not have to be outsourced abroad. It has proven to be a clear competitive advantage for our customers,” says Dirk Seckler, Co-CEO of Handtmann Light Metal Casting and Systems Engineering. Handtmann chose SW Automation GmbH, a custom machine builder based in Tettnang – in close geographical proximity to the Biberach site – as its plant manufacturer. Dirk Seckler: “The short distance to the manufacturer proved decisive given the tight schedule, as it allowed us to resolve coordination loops that would otherwise have taken days in just a matter of hours!”

 

Highly automated and scalable
The 48-volt battery system is designed for use in mild-hybrid vehicles: It supports the powertrain during everyday driving and powers the vehicle’s electrical functions. Right from the start of the project, the system was evaluated and adapted in collaboration with the premium automotive manufacturer to ensure it could be reproduced, was stable, and could be transferred to series production within a short time. On the assembly line, approximately 15 robots handle the majority of the more than 20 assembly steps; four employees control and monitor the system. The process includes thermal joining, bonding of the cell modules, potting with thermally conductive adhesive, as well as leak and electrical end-of-line testing. Each battery system leaves the line only after undergoing a complete inspection. The facility is designed for reliability: Two decoupled conveyor loops with buffer storage ensure that, in the event of a malfunction on one line, the other can continue to operate independently for up to one hour. Annual capacity is up to 600,000 units.

 

Bridging technology: 48-volt systems
48-volt battery systems play a strategic role in the transition to electric mobility: They effectively reduce CO₂ emissions from internal combustion engine vehicles without requiring a complete redesign of existing vehicle platforms, and can be integrated into existing production lines. “For suppliers, this means simultaneously managing the pressure to innovate, regulatory requirements, and cost efficiency while keeping pace with the speed of Asian competitors. For us, the project is proof that this combination is possible in Germany,” said Robert Fiesel, Head of Business Division Handtmann Systems Engineering. To date, the company has brought battery systems with a cumulative total capacity of 164 megawatt-hours into series production and operates its own battery test bench at its Biberach site with a rated power of 1.1 megawatts and a voltage range up to 1,200 volts.

 

Industrialization Partner from Baden-Württemberg 
With the start of series production of the 48-volt battery system, Handtmann is strengthening its position as an industrialization partner to the automotive industry. The range of services extends from component development and system validation in the company’s own high-voltage battery testing laboratory, through the setup of customized production lines, to series production with integrated quality control – for components used in both electric mobility and combustion engine technology. The company covers the entire voltage range from 48-volt applications to high-voltage traction battery systems. “With this project, Handtmann is making a significant contribution to the transformation of industrial value creation in Germany. The Biberach site exemplifies our approach, which combines technological expertise, high automation, and rapid scalability. What matters is not only the development of new vehicle models, but also the local capability to rapidly bring them to series production in accordance with European industrial, cost, and quality requirements,” said Robert Fiesel. Especially for suppliers, speed in industrialization expertise is increasingly becoming a strategic differentiator and a decisive factor for the long-term competitiveness of Germany as an industrial location.