Manufacturer of plastic gears, gearing components and plastic precision parts using the injection moulding process.
Werner Bauser GmbH
Wehingen (DE) · Kalisz (PL) · Hwaseong (KR)New on Amplifa
About Bauser
Werner Bauser GmbH, headquartered in Wehingen, develops and manufactures plastic gears, gear segments, worm gear components, housings and precision parts using the injection moulding process. Founded in 1962, the company manages the entire process from consulting, gear calculation and simulation (KISSsoft, Sigmasoft, Moldflow), through design and in-house toolmaking, to series production, quality assurance, assembly and logistics. With more than 70 injection moulding machines (25–300 t clamping force), multi-axis robotics and full automation, up to 750,000 parts are produced daily; manufacturing tolerances are in the µm range. Materials include reinforced, sliding-modified and high-performance plastics such as PA46 as well as hybrid components made of metal-plastic composites. Customers come primarily from the automotive, e-mobility, defence, building services, mechanical engineering and drive technology sectors. In addition to Wehingen, the company, with around 200 employees, operates a production site in Kalisz (Poland) and a joint venture in Hwaseong (South Korea).
- Site
- Wehingen
- Processes
- Plastic injection moulding process (gears, gear segments, gearing components, worm gear components,, Metal-plastic composites / hybrid components, Toolmaking (injection moulding tools), Prototypes made from original material / 3D printing, Simulation (KISSsoft, Sigmasoft, Moldflow): gear design, gear optimisation,, Design (CAD), Consulting: material substitution, material selection, gear calculation, gearbox design,, Assembly of assemblies (non-automotive parts)
- Materials
- PA46 (post-treated plastic), reinforced plastics, sliding-modified plastics, high-performance plastics, plastic (general, gearing technology), PA46, Reinforced plastics, Sliding-modified plastics
- Certificates
- IATF 16949:2016 (excluding product development), ISO 9001:2015, DIN EN ISO 14001:2015, DIN EN ISO 50001:2018 Energy management, ISO 9001, IATF 16949, ISO 14001, ISO 50001
- Founded
- 1962
- Employees
- 200
- Industries
- Automotive, E-Mobility, Defence technology, Building services & professional trades, Mechanical engineering, Drive technology
- 01
Consulting & Predesign
- 02
Gear calculation & gearbox design
- 03
Simulation (KISSsoft, Sigmasoft, Moldflow)
- 04
Design (CAD)
- 05
Prototyping / 3D printing
- 06
Toolmaking
- 07
Injection moulding production
- 08
Quality assurance
- 09
Assembly of assemblies
- 10
Logistics
Materials & Processes
PA46
Post-treated high-performance plastic, among other things with 30 % higher tooth root strength for garage door drives.
Reinforced plastics
For mechanically highly stressed gears and gearing components.
Sliding-modified plastics
Reduce friction and wear in gearbox applications.
High-performance plastics
For thermally and mechanically demanding operating conditions.
Metal-plastic composites
Hybrid components ensure higher force transmission in functional systems.
Injection moulding
Core process for gears, gear segments, housings and precision parts with tolerances in the µm range.
Toolmaking
In-house manufacture of injection moulding tools as the basis for precision across high production volumes.
3D printing / Prototyping
Realistic prototypes made from original material for component testing.
Locations
Wehingen
DEHeadquarters with production, design, toolmaking and logistics
- Lot size
- High production volumes
- Materials
- Plastics, PA46, hybrid components
- 70+ injection moulding machines (25–300 t clamping force)
- Multi-axis robotics
- Test bench for plastic gears
Kalisz
PLProduction site for assembly of assemblies (non-automotive)
- Materials
- Plastic
Hwaseong
KRJoint venture with Shinsung Autotech for the Asian market
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Plastic injection moulding process (gears, gear segments, gearing components, worm gear components,Plastics | µm range | – | – | high production volumes | PA46, reinforced plastics, sliding-modified plastics, high-performance plastics |
| Metal-plastic composites / hybrid componentsPlastics | – | – | – | – | Plastic, Metal |
| Toolmaking (injection moulding tools)Engineering | µm range | – | – | – | – |
| Prototypes made from original material / 3D printingAdditive | – | – | – | – | Plastic (original material) |
| Simulation (KISSsoft, Sigmasoft, Moldflow): gear design, gear optimisation,Engineering | – | – | – | – | – |
| Design (CAD)Engineering | – | – | – | – | – |
| Consulting: material substitution, material selection, gear calculation, gearbox design,Engineering | – | – | – | – | – |
| Assembly of assemblies (non-automotive parts)Assembly | – | – | – | – | Plastic |
| Test bench for mechanically and thermally highly stressed plastic gearsTesting | – | – | – | – | – |
| Quality assurance to automotive standardsTesting | – | – | – | – | – |
5 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Injection moulding machines | – | 82 | – | – | Wehingen (D) / Kalisz (PL) / Hwaseong (KR) |
| Injection moulding machines (clamping force 25–300 tonnes) | – | 70+ | – | – | Wehingen |
| All-electric injection moulding machines | – | 5 | – | 2023 | – |
| Multi-axis robotics (automation) | – | – | – | – | – |
| Test bench for plastic gears | – | – | – | – | – |
Additional services
Quality & Certifications
Quality assurance is carried out to automotive standards; a dedicated test bench tests mechanically and thermally highly stressed plastic gears. The company is certified to IATF 16949, ISO 9001, ISO 14001 and ISO 50001.
| Evidence | Wehingen |
|---|---|
| ISO 9001 | |
| IATF 16949 | |
| ISO 14001 | |
| ISO 50001 |
History
- 1962
Company founded by Werner Bauser
- 1963
Production of the first gears using plastic injection moulding technology
- 1975
New building with 2,000 m² of production space
- 1986
First site expansion
- 1999
Second site expansion
- 2006
Completion of the third site expansion; founding of the production site in Kalisz, Poland
- 2007
Expansion of the warehouse and logistics area
- 2011
180 employees, 10,700 m² of production space
- 2015
Joint venture with Shinsung Autotech in South Korea
- 2017
Third site expansion with CO2-reducing measures
- 2018
200 employees, 14,600 m² total area; commissioning of two 20 kVA pre-switching units
- 2021
Commissioning of the first photovoltaic system
- 2022
Commissioning of the second photovoltaic system
- 2023
Investment in 5 all-electric injection moulding machines