Specialist in mechanical attachment, machining and assembly of components for high-performance brake systems
ABC – Advanced Brake Components GmbH
Eisenach (Am Kernberg 3, OT Neukirchen)New on Amplifa
About ABC GmbH
ABC – Advanced Brake Components GmbH, founded in 2003 and based in Eisenach (Thuringia), is a provider of components and services for technical brake systems. The core of production is a patented pin retention system based on a stud welding process, which mechanically joins the backing plate, underlayer and friction material of brake pads; the pins are made of brass (MS material). In addition, the company offers a full-service package in the mechanical machining of brake systems and pad carrier plates – including 2D/3D design, drawing creation, prototype machining, the insertion of wear indicators and the reworking of laser-cut or punched plates. The service portfolio is rounded off by the bedding-in of brake pads and brake discs on two friction coefficient test benches as well as disc assembly. Materials processed include steel, stainless steel, aluminium and titanium; CNC milling machines have been in use since 2013. Customers come predominantly from brake technology, motorsport and high-performance applications, including Porsche, Aston Martin and Audi RS. The company is certified to ISO 9001:2015.
- Site
- Eisenach
- Processes
- Stud welding (patented stud welding process for friction pads), Mechanical machining of brake systems and components (milling), Machining of pad carrier plates (any size, shape and material), Complete production of pad carrier plates according to drawings (DXF, DWG), 2D and 3D design, Machining and reworking of laser-cut or punched pad carrier plates, Prototype machining/creation, Bedding-in of brake pads and brake discs
- Materials
- Brass, Steel, Stainless steel, Aluminium, Titanium
- Certificates
- ISO 9001:2015, ISO 9001
- Founded
- 2003
- Employees
- Number not specified
- Industries
- Brake technology, Motorsport, High-performance applications, Automotive, High-performance applications
- 01
2D/3D design and drawing creation (DXF, DWG)
- 02
Machining of pad carrier plates (CNC milling)
- 03
Stud welding with patented retention system
- 04
Trimming of the welded pins according to drawing
- 05
Bedding-in of brake pads and brake discs
- 06
Disc assembly
- 07
Friction coefficient testing
Materials & Processes
Brass
Material of the pins for the patented retention system; leaves no marks or damage on the brake disc surface.
Steel
Material for pad carrier plates and components in mechanical machining.
Stainless steel
Used in the machining of pad carrier plates and brake system components.
Aluminium
Lightweight alternative in the machining of pad carrier plates and components.
Titanium
High-strength material for applications with extreme requirements in motorsport.
Locations
Eisenach OT Neukirchen
DEHeadquarters and production
- Materials
- Steel, stainless steel, aluminium, titanium, brass
- CNC milling machines (since 2013)
- Special machines for automated stud welding (in-house development)
- 2 friction coefficient test benches (since 2012)
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Stud welding (patented stud welding process for friction pads)Joining | – | – | – | – | Brass (MS material for pins), Steel (pad carrier plates), Stainless steel, Aluminium, Titanium |
| Mechanical machining of brake systems and components (milling)Machining | – | – | – | – | Steel, Stainless steel, Aluminium, Titanium |
| Machining of pad carrier plates (any size, shape and material)Machining | – | – | – | – | Steel, Stainless steel, Aluminium, Titanium |
| Complete production of pad carrier plates according to drawings (DXF, DWG)Engineering | – | – | – | – | – |
| 2D and 3D designEngineering | – | – | – | – | – |
| Machining and reworking of laser-cut or punched pad carrier platesMachining | – | – | – | – | – |
| Prototype machining/creationMachining | – | – | – | – | – |
| Bedding-in of brake pads and brake discsAssembly | – | – | – | – | – |
| Disc assemblyAssembly | – | – | – | – | – |
| Friction coefficient test bench testing (friction coefficient testing)Testing | – | – | – | – | – |
| Insertion of wear indicatorsAssembly | – | – | – | – | – |
| Trimming of welded pins according to drawingMachining | – | – | – | – | – |
| Complete reworking of finished pads with friction materialMachining | – | – | – | – | – |
3 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| CNC milling machines | – | – | – | 2013 | Eisenach OT Neukirchen |
| Special machine (stud welding, automated welding, in-house development) | – | – | – | – | Eisenach OT Neukirchen |
| Friction coefficient test bench | – | 2 | – | 2012 | Eisenach OT Neukirchen |
Additional services
Reference customers
Quality
ABC GmbH is certified to ISO 9001:2015 (DEKRA Certification GmbH, certificate 30311137/4) for the manufacture and distribution of components for technical brake systems. Quality assurance includes incoming goods inspection, first article inspection and final inspection of complex mechanical individual parts using mechanical and optical metrology as well as two friction coefficient test benches.
| Evidence | Eisenach OT Neukirchen |
|---|---|
| ISO 9001 |
History
- 2003
Foundation in Buchenau (Thuringia) with two employees; development of the patented pin retention system.
- 2003
Switch to automated welding; relocation to the Eisenach OT Neukirchen site.
- 2004
Construction of a new production hall as well as an increase in machinery and staff; first production on automated welding and integration of mechanical machining, bedding-in and disc assembly.
- 2012
Commissioning of two friction coefficient test benches for the professional bedding-in of brake pads and brake discs.
- 2013
Expansion of production through the use of CNC milling machines.
- 2016
Establishment of the disc assembly department.
- 2019
Construction of a new logistics hall.
- 2020
Renewal of ISO 9001 certification by DEKRA (certificate 30311137/3).
- 2023
Renewal of ISO 9001 certification by DEKRA (certificate 30311137/4, valid until 2026).