Manufacturing of custom bent parts and welded assemblies from tubes and profiles – all from a single source.
Schuster Rohrbogen GmbH & Schuster & Co. GmbH
Zeithain · MannheimNew on Amplifa
About us
The Schuster Group, comprising Schuster Rohrbogen GmbH in Zeithain (Saxony) and Schuster & Co. GmbH in Mannheim, manufactures custom bent parts and welded assemblies from tubes, profiles and special profiles for customers from all industrial sectors. The service portfolio includes mandrel bending from 4 to 220 mm tube outer diameter, profile rolling in the 3- and 4-roll process from 4 to 324 mm, combined bending processes, and 2D and 3D laser cutting on TRUMPF systems. In in-house specialized welding departments, assemblies are produced using, among others, TIG, MIG/MAG, MMA, TIG cold wire, oxy-fuel and plasma welding. Alloyed and high-alloy steels, stainless steels, aluminium, copper, brass, titanium and other materials are processed. The portfolio is complemented by in-house bending tool manufacturing, engineering design, tube end machining, hydraulic lines and surface treatment. Production ranges from one-off pieces and prototypes to series production.
- Site
- Zeithain
- Processes
- Tube bending (mandrel bending), Profile rolling (3- and 4-roll profile bending process), Combined bending processes (bending and rolling in a single step), Winding process (spiraling), 2D laser cutting of tubes, profiles and sheets, 3D laser cutting, Welding (TIG), Welding (MIG/MAG)
- Materials
- Alloyed and unalloyed quality steels, Stainless steels (high-alloy steels), Aluminium, Copper, Brass, Titanium, Platinum, Structural steel
- Certificates
- DIN EN ISO 9001:2015, AD 2000 Merkblatt W0 / TRD 100 / HPO, DIN EN 15085-2 (Welding of railway vehicles, level CL1), DIN EN 1090-2 EXC3 (Steel load-bearing structures), DIN EN 1090-3 EXC3 (Aluminium load-bearing structures), ISO 9001, AD 2000 W0 / TRD 100 / HPO, EN 15085-2 (Railway vehicles, CL1), EN 1090-2 EXC3 (Steel load-bearing structures), EN 1090-3 EXC3 (Aluminium load-bearing structures)
- Founded
- 1951
- Industries
- Mechanical engineering, Cabin construction, Vehicle construction / vehicle superstructures, Railway vehicle construction, Steel construction / load-bearing structures, Compressed air systems
- 01
Engineering & Design
- 02
Toolmaking (own bending tools)
- 03
Mandrel bending / profile rolling
- 04
2D and 3D laser cutting
- 05
Welded assembly manufacturing
- 06
Tube end machining
- 07
Surface treatment
- 08
Quality inspection / metrology
Materials & Processes
Alloyed and unalloyed quality steels
Base material for bent parts, structural steel hollow sections and welded assemblies.
Stainless steels (high-alloy steels)
For corrosion-exposed tube and profile constructions.
Aluminium
Lightweight material for bending, laser cutting and welding.
Copper
Non-ferrous metal for bent parts, among other things in piping applications.
Brass
Non-ferrous metal for cold-bendable tube and profile parts.
Titanium
For demanding bending and welding applications.
Platinum
Precious metal, processed by bending and rolling.
Structural steel hollow sections
Up to 180 x 120 mm with inner bend radius RI 700 mm, focus on safety-relevant applications.
Rectangular and square tubes
Can be machined with multiple bends in sequence.
Cast steel
Processed in the welding operation.
Locations
Zeithain
DEProduction and warehouse site (welding shop since 2025)
- Lot size
- One-off production to series production
- Materials
- Steel, stainless steel, aluminium, copper, brass, titanium
- Mandrel bending machines up to 220 mm (NC/CNC)
- 3- and 4-roll profile rolling machines
- TRUMPF TruLaser Tube 7000 (tube laser cutting)
- TRUMPF TruLaser Cell 7040 (3D laser)
- Specialized welding department
- Metrology
Mannheim
DEProduction and warehouse site in Mannheim-Friedrichsfeld
- Lot size
- One-off production to series production
- Materials
- Steel, stainless steel, aluminium, copper, brass, titanium
- Mandrel bending machines (conventional, NC/CNC)
- 3- and 4-roll profile rolling machines
- Specialized welding department
- Metrology
Parts
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Tube bending (mandrel bending)Forming | – | – | – | One-off production to series production | alloyed and unalloyed quality steels, stainless steels, brass, copper, aluminium, titanium, platinum, alloyed and high-alloy steels |
| Profile rolling (3- and 4-roll profile bending process)Forming | – | 18 m (round tube in the 3-roll process) | – | – | Round tubes, Structural steel hollow sections, Rectangular and square tubes, Angles, U-profiles, T-beams, I-beams, Special profiles, Aluminium, Copper, Brass, Titanium, Platinum |
| Combined bending processes (bending and rolling in a single step)Forming | – | – | – | – | – |
| Winding process (spiraling)Forming | – | – | – | – | – |
| 2D laser cutting of tubes, profiles and sheetsMachining | – | 6500 mm (finished part length) × max. outer diameter/circumscribed | 40 kg/m | – | Structural steel (max. 10 mm at 90°), Stainless steel (max. 8 mm at 90°), Aluminium (max. 5 mm at 90°), Copper/brass (max. 5 mm at 90°) |
| 3D laser cuttingMachining | – | – | – | – | Structural steel (max. 8 mm at 90°), Stainless steel (max. 6 mm at 90°), Aluminium (max. 5 mm at 90°) |
| Welding (TIG)Joining | – | – | – | – | Unalloyed steels, Low-alloy and high-alloy steels, Aluminium, Cast steel, Copper, Titanium, Special metals |
| Welding (MIG/MAG)Joining | – | – | – | – | Unalloyed steels, Low-alloy and high-alloy steels, Aluminium, Cast steel, Copper, Titanium, Special metals |
| Welding (MMA)Joining | – | – | – | – | Unalloyed steels, Low-alloy and high-alloy steels, Aluminium, Cast steel, Copper, Titanium, Special metals |
| Welding (TIG cold wire)Joining | – | – | – | – | Unalloyed steels, Low-alloy and high-alloy steels, Aluminium, Cast steel, Copper, Titanium, Special metals |
| Welding (oxy-fuel)Joining | – | – | – | – | Unalloyed steels, Low-alloy and high-alloy steels, Aluminium, Cast steel, Copper, Titanium, Special metals |
| Welding (plasma)Joining | – | – | – | – | Unalloyed steels, Low-alloy and high-alloy steels, Aluminium, Cast steel, Copper, Titanium, Special metals |
| Welded assembly manufacturing (tube connections, welding fittings, welding flanges)Joining | – | – | – | – | Unalloyed steels, Low-alloy and high-alloy steels, Aluminium, Cast steel, Copper, Titanium, Special metals |
| Toolmaking (in-house bending tool manufacturing)Engineering | – | – | – | – | – |
| Fixture construction, engineering design, DMF & DTCEngineering | – | – | – | – | – |
| Tube end machining (sawing of ends etc.)Machining | – | – | – | – | – |
| Surface treatmentSurface | – | – | – | – | – |
| Hydraulic linesJoining | – | – | – | – | – |
4 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Mandrel bending machines (conventional, NC- and CNC-controlled) | – | – | Tube outer diameter 4–220 mm; bend radii from 1.2 x D | – | Zeithain and Mannheim |
| 3- and 4-roll profile rolling machines (conventional, NC- and CNC-controlled) | – | – | Tube outer diameter 4–324 mm | – | Zeithain and Mannheim |
| 3D laser system | Trumpf TruLaser Cell 7040 | – | 5-axis gantry with rotary axis; X 4,000 mm, Y 1,250 mm, Z 800 mm; CO2 3.2 kW | – | – |
| Tube laser cutting machine | Trumpf TruLaser Tube 7000 | – | max. round tube Ø 254 mm, max. raw material length 9,100 mm, max. finished part length 6,500 mm, | 2024 (Inve | Zeithain |
Additional services
Quality
The quality management system is certified according to DIN EN ISO 9001:2015, as a manufacturer according to AD 2000 Merkblatt W0/TRD 100/HPO, and as a certified welding company according to DIN EN 15085-2 (CL1) and DIN EN 1090-2/-3 (EXC3). Since 2020/2021, investments in modern metrology have been made at both locations.
| Evidence | Zeithain | Mannheim |
|---|---|---|
| ISO 9001 | ||
| AD 2000 W0 / TRD 100 / HPO | ||
| EN 15085-2 (Railway vehicles, CL1) | ||
| EN 1090-2 EXC3 (Steel load-bearing structures) | ||
| EN 1090-3 EXC3 (Aluminium load-bearing structures) |