The supplier Osbra, based in Bad Wörishofen, Germany, is a sought-after partner for numerous premium automotive brands such as Mercedes-AMG, Porsche, BMW Alpina, Aston Martin, and Maybach. Despite the generally tense situation in the industry, the company is recording sustained growth. With around 400 employees, Osbra generates annual sales of over €80 million.
Choosing between injection molding and polyurethane processing
Deciding whether it is worth investing in injection molding tools or whether the higher unit price for processing polyurethane (PUR) is economically viable is part of everyday business at Osbra. The quantities range from around 2,000 components per year for the Aston Martin DBX model to 40,000 for the BMW X6. The two technologies are often combined: large-format or complex components are made from PUR, while smaller add-on parts are injection molded. The corresponding systems are supplied by Krauss-Maffei, with whom Osbra has been working closely for many years.
Sustainable production at Osbra with efficient plant technology
In its newly constructed production building, equipped with heat recovery and photovoltaics for complete self-sufficiency in power, Osbra operates five injection molding machines from Krauss-Maffei. The clamping forces range from 1,600 kilonewtons for the fully electric “PX” model to 14,500 kilonewtons for the “MX” model. These are supplemented by 13 mold carriers with clamping forces of up to 5,000 kilonewtons and component weights of up to twelve kilograms. The equipment includes magnetic clamping plates for reduced setup times, wider plates in the “PX 161” model, and a wear-resistant screw in the “MX 1300” model. Processes such as gas injection and chemical foaming can be integrated as options.
Digital assistance systems for small-batch production
All machines are equipped with LRX linear robots and a digital package from Krauss-Maffei. This includes digital solutions for process, production, and service improvement. The APCplus function is particularly advantageous for frequent mold changes in small batch production. It automatically adjusts the switchover point from injection to holding pressure based on the melt viscosity, ensuring consistent component weights from the very first shot.
Osbra complete solutions up to batch size 1
Osbra offers OEMs complete solutions ranging from development and prototyping to series production of entire assemblies. Electronic components and all cabling are also integrated. One example is the painted bumper for the Mercedes “G-Class” with a shot weight of 2.8 kilograms made of polypropylene and integrated PDC sensors. The radiator grille of this model consists of two covers with differently hot-stamped chrome accents. Osbra also processes carpet and textile materials for the vehicle interior.
New requirements due to electric variants
Since 2024, the “G-Class” has been available as a fully electric version for the first time. Two new components distinguish the model: an LED-illuminated radiator grille and a two-part storage box on the rear door. The latter replaces the previous spare wheel and houses the charging cable. It can be electrically locked from the driver's seat and had to meet the highest requirements for tightness and climate resistance. It was developed in collaboration with the manufacturer Mercedes.
Osbra expansion plans in preparation
To cover future projects, Osbra plans to expand its production facilities with an additional production hall. The purchase of a large mold carrier and two new polyurethane systems is planned. A corresponding offer has already been requested from Krauss-Maffei.
