NEWS

<p style="text-align: center;"><img src="/ueditor/php/upload/image/20260610/1781095668132503.png" title="1781095668132503.png" alt="1.png"/></p><p><span style="font-size: 14px;">To further ensure manufacturability, Gehring Technologies integrates simulation-based tools into its digital process chain. The Twist Simulator virtually models plastic deformation processes during hairpin twisting. Material properties, geometric parameters, and process-specific boundary conditions are incorporated, enabling a realistic simulation of the entire process. This simulation provides a reliable basis for decision-making in both development and production. Deviations between target geometry and expected process outcomes become visible at an early stage, allowing design adjustments before physical prototypes are produced. Hausmann explains: “We simulate the process virtually and obtain reliable insights into manufacturability. The data can be directly transferred to the real process, ensuring high reliability and reducing the risk of costly iterations.” For users, this results in increased confidence. Development decisions are no longer based solely on experience but on simulation-driven predictions. Reference applications demonstrate a high correlation between simulated and actual process results, further strengthening trust in digital validation. In addition, PinStudio enables specialized geometric quality assessment of hairpins. The analysis module processes 3D measurement data from various systems and performs automated target-versus-actual comparisons. Deviations are not only detected but also localized within the process, allowing error-causing bending steps to be identified and corrected. The system’s value lies in its transparency and ease of use. The interface is intuitive, and evaluations are automated and reproducible. PinStudio supports both existing customers seeking statistical process monitoring and users developing their own hairpin designs. Hausmann summarizes: “PinStudio makes process deviations visible. The evaluation is automated, reproducible, and independent of the operator—creating a level of comparability that is difficult to achieve with conventional measurement methods.”</span></p><p><span style="font-size: 14px;">Series-Oriented Prototyping as a Bridge to Industrialization Based on digitally validated development data, the process transitions into physical prototype manufacturing. Gehring Technologies employs a modular tooling concept that combines series-oriented base modules with component-specific rapid prototyping elements. Standardized fixtures are reused, while product-specific adaptations are primarily produced via additive manufacturing or fast sheet-metal processing. This approach significantly reduces tooling costs and lead times. While traditional prototyping projects often take several months, A-samples can now be realized within six to twelve weeks. Project costs typically decrease by more than 40 percent. A key factor is the consistent alignment with series production. Prototypes are manufactured on machine platforms closely aligned with future production systems. Dr. Wiens highlights: “Our prototypes are not produced on isolated test rigs. They are manufactured on series-oriented machines - ensuring transferability to production from the very beginning.”</span></p><p><span style="font-size: 14px;">Seamless Integration of Digital Development and Physical Validation Overall, digital development approaches and physical prototyping are deliberately interlinked. While digital tools accelerate and secure product development, physical manufacturing serves as a reference for validating virtual designs. Prototyping thus increasingly becomes a validation step within an integrated development strategy.</span></p><p><span style="font-size: 14px;">At the core lies a consistent data model functioning as a digital twin across all process stages. The parametric development model serves as a reference for CAD geometries, simulation models, measurement data, and tooling and process derivations. Design changes are automatically transferred to downstream manufacturing and quality assurance processes, significantly reducing discontinuities between development, production, and quality control. This creates a new dynamic for development teams. Variant studies can be accelerated, design changes evaluated immediately, and manufacturability ensured at early stages. Production teams benefit from series-oriented prototypes, reproducible quality data, and more stable ramp-up processes— especially in projects with low initial volumes or new drive concepts. Beyond Automotive: Expanding Application Potential&nbsp; The combination of digital development platforms and series-oriented prototyping also opens new opportunities beyond traditional automotive applications. Commercial vehicle drives, industrial electric motors, and customer-specific special applications can be realized using similar development strategies. Companies without in house hairpin development expertise gain access to an end-to-end development and industrialization approach. Gehring continues to expand this strategy, further developing its digital toolchain and integrating additional process modules. The goal is tighter system integration and greater involvement of external users in early development phases. As a result, prototyping is evolving from a classical development stage into a strategic component of digital product creation. Physical manufacturing becomes proof of the virtual design, while a scalable platform emerges - reducing development times, minimizing industrialization risks, and significantly shortening time-to-market for new electric drive systems. By consistently integrating simulation, development, and production, Gehring Technologies positions itself not only as a machine manufacturer but as a system partner for industrial electric motor production. The digital twin serves as the central anchor of a development methodology that significantly accelerates the transition from concept to series-ready product.</span></p>