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Four Disciplines.
One Production Line.
Molding, tooling, engineered products, and automation are not separate departments here. They share a floor, a data model, and a single quality system — which is why a design change reaches a validated part in weeks, not quarters.
PORTFOLIO
What We Do
Four disciplines, all in-house on one floor and one quality system. Here is each in detail — what it covers, where the limits are, and why owning it end-to-end keeps a change in one from blindsiding the other three.
01 — PRODUCTION
Multi-component and high-tonnage molding for structural and under-hood parts.
02 — METROLOGY
Micron-level tool fabrication paired with 3D optical coordinate metrology.
03 — COMPONENTS
Kinetic assemblies, thermal housings, and functional automotive subsystems.
04 — AUTOMATION
Robotic cells, AI optical inspection, and automated assembly pathways.
01 Production
Injection Molding
Multi-component and high-tonnage molding for the parts that fail expensively — structural carriers, under-hood housings, sealing-critical enclosures.
- 2K & 3K multi-component
- 50 – 1,300 tonne clamping
- Hybrid overmolding
- In-mold labelling & decoration
- Gas- and water-assist
- Cleanroom-adjacent molding
CELL // MLD-1300T
LAB // CMM-02
02 Metrology
Tooling & Measurement
We build the tool and we measure what it makes — micron-level fabrication paired with 3D optical coordinate metrology, so the people cutting steel and the people signing off parts read the same numbers. First-article reports are generated from the same scan data that feeds our SPC loop, so there is one measurement truth from tryout through series.
- 5-axis high-speed CNC
- Wire & sinker EDM
- Blue-light 3D scanning
- CMM fixture validation
- GD&T first-article reporting
- Climate-controlled metrology lab
03 Components
Engineered Products
Give us a function, not just a drawing — kinetic assemblies, thermal housings, sealed enclosures — and we engineer the part that delivers it. We take responsibility for the function, not just the geometry — which means we own the DFMEA, the tolerance stack, and the validation plan alongside your engineers.
- Kinetic & latching assemblies
- Thermal management housings
- Fluid reservoirs & routing
- Sealed electronic enclosures
- Vibration-welded assemblies
- Leak- and burst-tested at EOL
ASSY // EP-4470
CELL // ROB-08
04 Automation
Precision Automation & Robotics
Robotic cells, AI optical inspection and automated assembly built around the part — not bought off a catalogue and forced to fit. We build our own cells, so when a program ramps we re-tool the automation in-house instead of queuing behind an integrator’s backlog.
- 6-axis robotic take-out
- Automated assembly cells
- AI optical defect detection
- Vision-guided pick & place
- Automated packing & traceability
- Line-side data historian
HOW WE WORK
Concept To Series
Four stages, all under one roof. The handoffs that usually cost programs their launch date simply do not exist here.
01
Design-for-manufacture review with your team, then moldflow, thermal and structural analysis — all before any tool steel is cut.
02
HKR builds the mold or die to the validated model, then in-house tryout presses qualify it and produce first articles.
INFRASTRUCTURE
Equipment & Materials
A representative extract. Full machine and material lists are available under NDA on request.
Machine Envelope
Injection presses50 – 1,300 t
Multi-component units2K / 3K
5-axis high-speed CNCUp to 42,000 RPM
EDM wire & die sinking± 2 µm
Optical 3D scanningBlue-light, 8 µm
Robotic cells6-axis, 28 units
Processed Materials
PA6PA66-GF35PBTPP-TD20PPSPPAPOMABS / PC-ABSPCTPE / TPVLSRPEEKLFTRecyclate blends
Glass- and mineral-filled grades are processed on wear-protected screws and hardened tool steels. Where a program targets recycled content, we qualify the recyclate blend through the same moldflow and mechanical validation path as virgin resin — no exceptions, because a sustainability target that fails PPAP helps nobody.
CONNECT
Bring Us The Hard One.
Tight tolerance, awkward geometry, or a launch date that already slipped? Those are the programs we are built for.
Global engineering and manufacturing partner providing high-precision tooling, plastic injection molding, and automated robotic systems for the tier-1 automotive sector.
IATF 16949 / ISO 9001 CERTIFIED
Capabilities
Headquarters
Rea Automotive Systems Corp.
Industriestraße 48
D-70565 Stuttgart, Germany
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