(Parsdorf, 02.06.2025). The indispensable partner comes from Bad Wörishofen, Germany: Many automotive OEMs rely on the cooperation with Osbra GmbH for their luxury brands - and their technical expertise in the areas of injection molding and reaction process machinery. The KraussMaffei customer is growing sustainably and defying the general crisis. 400 employees generate annual sales of over 80 million euros.     

The best for every application: At what point is the high initial investment in injection molding worthwhile, and when can you accept the higher price per part that results from a lot of manual work and reworking for items made of polyurethane (PU)? At Osbra GmbH, this question is part of daily business. After all, the required quantities vary from around 2000 per year for the "volume model" DBX at Aston Martin to 40,000 for the BMW X6. The strengths of both processes are often combined and large items or those with significant wall thickness variations are produced using PU, while small add-on parts are injection molded. The system comes from KraussMaffei, and the two companies have been working together for a long time.

In Osbra's new production building - with highly efficient heat recovery and a photovoltaic system that covers up to 100 percent of its own requirements - five KraussMaffei injection molding machines with clamping forces ranging from 1,600 kN (an all-electric PX) to 14,500 kN (MX model) and 13 mold carriers (clamping force up to 5,000 kN, component weight up to 12 kilograms) are in operation. The equipment level is high in each case, starting with the magnetic clamping platens, which significantly reduce the set-up time when changing molds. One of the two all-electric PX machines has widened platens (PX 161) and a highly wear-resistant screw rotates in a MX 1300. Gas injection and chemical foaming are also possible.

All machines use LRX linear robots and the complete socialProduction package from KraussMaffei, which includes digital solutions for production, process and service control. The APCplus machine function, which adjusts the switchover point from shot to shot based on the melt viscosity and produces extremely weight-constant components right from the start-up, is also of interest for the frequent mold changes caused by the small series.

Osbra offers its customers an all-round package, from development and prototype construction to the delivery of complete assemblies, including electronic components and cabling, which leave the factory as a so-called ZB component, i.e. ready for assembly in the vehicle. For example, the completely painted bumper (2.8 kilogram shot weight, material polypropylene) with integrated PDC sensors (Park Distance Control) is produced for the G-Class.  The radiator grille of the same model features two covers and chrome accents, which are hot-stamped in three different colors. Osbra also uses carpet and textiles for interior components such as center consoles and headliners.

A fully electric version of the G-Class has been available to order for the first time since 2024 - and it features two highlights. In addition to a newly designed LED-illuminated radiator grille, a two-part storage box has also been created, which is located on the rear door where the spare wheel used to be. The charging cable is conveniently stowed in the box, which the driver can lock and unlock from the seat. The electronic components installed mean that the box had to be absolutely rainproof and pass the usual climate change tests without distortion. The development proved to be challenging, but it was a successful team effort between Mercedes and Osbra.     

For future projects, it will be necessary to expand production in Bad Wörishofen to include an additional hall with a large mold carrier and two polyurethane systems. The offer from KraussMaffei has already been requested.