PowerTower®

Forming, cutting, welding: As technology and system partner we lead you to the limits of feasibility. For more than 15 years we have been specializing on the cost-effective production of metal microstructure plates. Using the Graebener® PowerBoxx® and the Graebener® PowerTower® you can realize microstructures for various metals with a wall thickness as low as 50 µm (0.05 mm) – in a highly accurate, economic and reliable way. Benefit from our long-term experience and our prototyping center.

PowerTower®

Forming, cutting, welding: As technology and system partner we lead you to the limits of feasibility. For more than 15 years we have been specializing on the cost-effective production of metal microstructure plates. Using the Graebener® PowerBoxx® and the Graebener® PowerTower® you can realize microstructures for various metals with a wall thickness as low as 50 µm (0.05 mm) – in a highly accurate, economic and reliable way. Benefit from our long-term experience and our prototyping center.

OverviewConceptEngineering & Prototyping

Metal microstructures are more sought-after than ever before. However, for forming specialists that means pushing the limits. Where conventional production processes fail, the patented Graebener® machines PowerBoxx® and PowerTower® are just beginning to leverage their strengths. Based on the core competences forming, cutting and welding we have been among the leading developers and manufacturers of production lines for the cost-effective production of metal microstructure plates for more than 15 years.

From engineering and prototyping services through small series production up to the customized production lines we support and accompany you on the path to a new and pioneering dimension of the forming technology.

Today, we are one of the pioneering companies in the fuel cell sector when it comes to the production of separator plates. Based on our long-term development in the business area "New Technologies" we provide the know-how of the entire value-added chain for the production of highly precise and powerful separator plates for LT-PEM, HT-PEM, DMFC and SOFC fuel cells as well as for the LT-PEM electrolysis. Numerous application tests, including a Range Extender project for the Fiat 500, give proof of that.

Microstructures have also become increasingly interesting for other fields of application: Above all for manufacturers of heat exchangers and developers of redox flow batteries.

Benefit from our long-term experience and our comprehensive network of partners.

We have developed the patented prototyping system PowerBoxx® and the patented series technology PowerTower® especially for the economic production of metal microstructures. Both concepts are based on an optimized hydroforming process. Various metals with a wall thickness from 50 µm are formed in a highly precise way by means of a fluid operating media at a closing force of up to 6,500 tons and a pressure of up to 4,000 bars – thanks to a special Graebener® compensation system, without any deflection of the press table.
Compared with classic forming methods such as punching or deep-drawing, our optimized hydroforming process offers many advantages technology as well as economy wise:

  • Reproducible forming results at a wall thickness starting at 50 µm
  • Gentle forming of precoated materials
  • Integrated process control
  • Considerably lower tooling costs
  • Almost no tool wear
  • High productivity thanks to patented multipurpose tool
  • Resourcefriendly ramp-up of production lines

As special machine manufacturer and as one of the pioneers in this field we have been developing the hydroforming process since the mid-80ies. Based on this pool of experience we realize your customized solution tailored to your individual market demands.

Reference results of our technology in detail:
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Forming
Forming
  • Material: 1.4301
  • Wall thickness: 50 µm
  • Pitch: 0.75 mm
  • Channel depth: 0.25 mm
  • Result: extremely accurate, high repeat accuracy and reproducibility

 

Laser Cutting
Laser Cutting
  • Material: 1.4301
  • Wall thickness: 50 µm
  • Pitch: 0.75 mm
  • Channel depth: 0.25 mm
  • Result: precise cut, burr-free, no heat tinting

 

Laser Welding
Laser Welding
  • Material: 1.4301
  • Wall thickness: 50 µm
  • Laser spot diameter: less than 100 µm
  • Channel depth: 0.25 mm
  • Result: no weld seam errors, high position accuracy, small seam widths

 

When developing new production technologies, we benefit quite significantly from our process know-how gained in the classic business areas. As technology and system partner we can also offer you the services of our own world-class hydroforming prototyping center.
A total of four hydraulic presses with closing forces of 1,500, 2,500, 6,500 and 10,000 tons are available for test series and small series production. In addition to this, we also support you in the area of design and engineering.

Brief summary of our performance profile:

MaterialsStainless steels, titanium, copper, plated materials, precoated materials
Wall thicknessfrom 50 µm
Lot sizefrom initial sample to small series
Workpiece sizefrom 1 cm2 to 12 m2
Press forces1,500 to 10,000 tons

In case of questions regarding seal or coating concepts you can benefit from our tight-knit network of partners. As integral part of the fuel cell industry and Board Member of the VDMA (German Engineering Federation) work group fuel cells we have been in close contact with the most experienced developers and manufacturers for many years.

You buy a Graebener® solution

You get more than just a machine or system. You get a reliable partner who understands your processes and who develops the optimum solution for the market challenges together with you.

Customer promise