“How can we make this process even more efficient and precise?” It’s  a question that continually drives Heinz Dünne, managing director and co-founder of Ferro Umformtechnik.

A pioneering force  

For 30 years, Ferro Umformtechnik has been a leading supplier to the international height access and lifting, commercial vehicle, and rail vehicle industries. The company plays a pioneering role in developing new applications and manufacturing processes, while continuously investing in advanced sheet metal fabrication and forming technologies. 

Through this approach, Ferro has transformed itself from a traditional parts manufacturer into a full-service supplier of complex, large components. Today, the site in Stadtlohn covers 34,000 m², with a second facility in Poland covering around 8,000 m², producing parts up to 4 metres. 

“It was clear from the outset: we had to be able to do something that others couldn’t,” says Heinz Dünne. “Thirty years ago, I pitched the idea of a 2.5D bevel head for laser cutting machines to various manufacturers. One machine builder picked it up. This made it possible to combine cutting and beveling in a single operation – a decisive gain in both efficiency and quality. That was the start of Ferro Umformtechnik.” 

“Around 2001, the next technological leap followed: laser welding. Ferro adopted this process early on in sheet metal forming and developed it further to enable structurally optimised components and more efficient manufacturing processes. The aim was to achieve high-quality welded joints with minimal rework and high seam quality. The principle remains the same: to use technology to make processes more efficient, improve products, and ultimately make our customers stronger and more competitive.”

Strong partnership 

“The biggest challenge, however, was handling and bending large, complex components in a safe, repeatable and reliable way.” 

For Dünne, it was clear: “Automation was the next logical step.” 

“At the EuroBLECH exhibition, the Synchro-Form press brake from LVD immediately caught our eye. It was exactly what we were looking for: a solution for fully automated bending of large profiles.” 

Synchro-Form processes sheet metal with a tensile strength of 1,300 N/mm². Its modules position workpieces precisely using magnets and a laser measurement system, whilst multi-axis Synchro-Form modules continuously measure the bending angle and adjust automatically via the Touch-B control system. 

The two companies also shared a common vision. Heinz Dünne recognised the potential for a strong, long-term partnership right from the start. 

Carl Dewulf, CEO of the LVD Group, reflects this same view: “With Ferro, we do not operate in a traditional customer-supplier relationship, but as equal partners who understand, challenge, and strengthen each other. We share the same drive to think ahead and innovate. This mutual respect and shared ambition ensure that we continue to grow together.” 

Teams Ferro and LVD that made the project a success.

Guaranteed process reliability 

Dünne continues: “Two years later, at EuroBLECH, we signed the contract for our first Synchro-Form 1600/142: a machine with 1,600 tons of pressing force and a 14-meter working length. At the time, this was our largest single investment. And yes, it was exciting, because at that point we still didn’t know whether all the tests with the trial parts would be successful.” 

During the intensive collaboration between the engineering teams of both companies, LVD also realised that Ferro is a partner that actively contributes ideas.  

“Ferro is a customer that constantly challenges us to go one step further,” says Steven Lucas, International Press Brake Product Manager at LVD. “High-strength steel grades are becoming thinner, yet at the same time stronger and more difficult to bend. Ferro provides us with the materials to thoroughly test the machine. As a result, we as a manufacturer have learnt just as much – it’s a collaboration that makes us stronger technologically.” 

“The introduction of Synchro-Form has permanently transformed production at Ferro. Thanks to this technology, the key process steps can now be implemented adaptively. This has made the process more predictable and repeatable, while minimising the operational effort. Manual interventions, such as component handling or test bends, are no longer necessary. Instead, the entire bending process takes place in a continuous, controlled sequence,” adds Heiko Martin, Sales Director at LVD GmbH. 

The largest Synchro-Form  

Heinz Dünne: “For us, process reliability is the most important factor. Thanks to this machine, we can produce the planned number of units every day at a consistent quality level. Synchro-Form has prepared us for the future.” 

Another important aspect is the design of ergonomic workstations. Against the backdrop of demographic change, reducing physical strain when handling large and heavy components is particularly important. This enables skilled employees to remain healthy and continue working at Ferro in the long term, ideally until retirement. 

The successful collaboration with LVD has since been continued. 

 

“Last year, we also commissioned a Synchro-Form 3000/163 press brake. Even larger, even more powerful: 3,000 tons of pressing force and a 16-meter working length. It is the largest Synchro-Form ever built by LVD. When I stood in front of the machine for the first time, I thought: What an ingenious feat of engineering!” 

Ferro will surely continue along its chosen path of automation. Heinz Dünne is not standing still: “We are continuously developing our manufacturing processes and remain committed to exploring new possibilities in sheet metal forming.” 

PROFILE

Company: Ferro Umformtechnik 

Since 1996 

Industry: height access and lifting industry, commercial vehicle, and rail vehicle industries 

Works with: high-strength steels S1100 and S1300, with a tensile strength of 1,300 N/mm²  

LVD Installations:  

  • Synchro-Form 1600/142 
  • Synchro-Form 3000/163 

LVD Software: CADMAN-B 

Website: www.ferro-umformtechnik.com/en