FSW prototyping & pre-serial production

In the automotive industry, most components pass through multiple development stages – from initial functional samples (A-samples) and validated prototypes (B-samples) to near-series pre-production projects (C-samples). We support our customers at every stage, provide targeted assistance with specifications, and actively contribute to the component design. It is precisely during these phases that the foundation is laid for whether a product can be produced reliably, economically, and at the desired quality in series production. Therefore, we attach great importance to realistically representing all relevant influencing factors with meaningful results, ensuring that your components are optimally prepared for series production step by step.

In our pre-series production, we handle the entire fixture construction in-house – from design and manufacturing to assembly. This end-to-end capability allows us to implement adjustments quickly and precisely, so that valuable insights feed directly into series production. At the same time, we ensure the optimal design of the FSW tools. Based on lifetime analyses and realistic trials with your original components, we can immediately implement and verify modifications. The result is tools that not only guarantee the highest process reliability but also achieve maximum service life – a decisive advantage for later series production. Additionally, we already produce in the pre-series using near-series process parameters and clamping sequences. This provides reliable information on weld quality, cycle times, and process stability during the development phase. Our infrastructure is ideally equipped for this: alongside welding, we perform all accompanying inspections and services – from milling operations and optical 3D measurements by GOM to extensive leak tests. All components work seamlessly together to form a coordinated overall package.

With Stirtec, you gain a partner who consolidates all steps and systematically supports your project from the first test part to a robust series solution.