… from a wide range of materials. Our in-house tool manufacturing department, state-of-the-art machinery, and highly skilled staff ensure the highest precision and stable processes. We are consistently expanding our digital solutions and deploying them strategically to further optimise processes and increase transparency. This results in cost-effective solutions with exactly the precision required to offer a wide range of options for further processing and subassembly manufacturing.

This is where prototypes and production equipment – including high-performance progressive tools – are developed, and where repair and maintenance services are provided.

Prototypes – Manufacturing of A and B samples

Depending on your requirements, we efficiently manufacture parts or part variants for your development or pre-series production under conditions similar to those of series production. We would be pleased to contribute our expertise to your development and optimisation process. This is the only way to minimise process risks early on, find technically sound solutions, and identify cost savings.

We support your prototyping and optimisation phases with:

• Offering variants
• Consulting and testing to assess manufacturability
• Testing with different materials or coatings
• Prototypes manufactured close to series production
• Testing and Sampling
• Process diagrams and flowcharts
• FMEA

Prototype manufacturing for near-series testing – Variations in geometry and material can be implemented quickly.

New tool manufacturing and fixture design

In the field of new tool manufacturing and fixture design, Windisch produces the following items, depending on the requirements:

• High-performance progressive tools
• Compact superstructures in column-guided    frames
• Plate guide tools
• Drawing tools
• Progressive cut tools
• Bending tools
• Assembly fixtures
• Clamping and welding fixtures
• Production auxiliary means

The tooling concept is designed during the quotation phase with the goal of achieving cost-effective and stable production. In doing so, we take into account your requirements regarding materials, coatings, part geometry, tolerances, and order quantities. The operating weight and material utilisation are also adjusted to ensure reliable and cost-effective production.
Once commissioned, the concept will be fully developed and refined into a solution ready for implementation.
We also reliably handle any necessary adjustments and optimisations to customer-provided tools. If CAD data is not available, we digitalise the relevant moving parts of the tool, thereby laying the groundwork for cost-effective spare parts production.

Tool design

Tool design is typically carried out in 3D in collaboration with an external partner, and in some cases internally using SolidWorks.

CNC

We program the CNC machines in-house using PEPS software.

Tool maintenance and repair

Our tool maintenance and optimisation department, along with our production tooling and technical equipment maintenance teams, ensure tool availability and, consequently, efficient, high-quality, and reliable parts production. This also includes keeping important spare parts and standard parts in stock as well as manufacturing new ones. The valuable tools and spare parts are stored neatly and securely in the vertical carousel.

Small-series production

The tool manufacturing department also produces parts in small series. The process steps for complex workpieces are often numerous and are carried out with precision by our toolmakers.

Additional services

• CNC milling of complex parts with high dimensional accuracy
• Surface grinding to ensure the tightest tolerances and high-quality surfaces
• Wire eroding for precise contours and filigree cutting geometries with smooth cut surfaces
• Blasting for targeted surface treatment and process preparation

Production — Punching, welding, laser cutting, pressing, drawing, bending … Windisch manufactures your parts efficiently and precisely

In our precision punching shop, we manufacture products for you using 32- and 63-ton Haulick Roos and 60-ton Malucha/Raster precision punching machines, supplemented by Vester tool monitoring and lubrication systems as well as other peripheral equipment such as straightening machines.

Materials. Depending on the part, strips ranging from 0.10 to 3.00 millimetres in thickness and up to 220 millimetres in width can be processed. Camera-based inspection of test and measurement features with automatic selection is possible.
Materials include, depending on requirements, e.g., tinplate, carbon steels, galvanized steels, stainless steel, and spring steel; bimetals; plated materials; partially or fully coated, foil-coated, or brushed raw materials or punched strips; nickel; aluminium alloys; copper and alloys such as brass, bronze, and copper-beryllium; or specialty materials such as Hastelloy, HILUMIN®, and NICOR®.

Extras. Additional operations, such as thread cutting or thread forming, can be integrated into the progressive tools. In-house post-processing of the products is also possible, such as degreasing, vibratory finishing, tumbling, ultrasonic cleaning, brushing, and laser marking.
We outsource electroplating/surface treatment, KTL coating, electropolishing, etc.

Reel-to-reel. We punch your pins from coil to punched strip. Reel-to-reel pins are available starting at a pin width of 0.50 mm and a material thickness of 0.60 mm – even with subsequent coating. Depending on your needs, we can also provide a service to separate the punched strip, which may be partially coated, for example, into individual parts or contact combs.

NEW: With a table length of 1,250 mm, another 63-ton Haulick-Roos automatic punch press has been available since October 2025, offering those sometimes crucial extra 250 mm.

Laser cutting. With our TruLaser Cell 3000, we can process virtually all common metals with precision and flexibility—from stainless steel and steel to brass, bronze, copper, and aluminium alloys. Depending on the component geometry and material, parts measuring up to 600 × 800 mm with material thicknesses ranging from 0.05 to 3.00 mm can be manufactured with the highest precision, with a positional deviation Pa of just 0.015 mm (absolute). Upon request, machining can be performed using production-grade materials, enabling the creation of realistic prototypes and pre-production parts. Furthermore, the TruLaser Cell is used to produce regrinding pads for tool manufacturing.

Note: Due to the geometry of the part, it is important to note that the condition and strength of the material may change in the edge area or throughout the entire component as a result of heat input during laser cutting. If this is critical for further processing and testing, circuit boards should also be punch-cut for prototypes.

Laser welding. Due to the high processing speed, only minimal heat is transferred to the component, allowing for particularly distortion-free and clean joints. Laser welding offers a reliable alternative to processes such as press fitting or resistance welding, particularly in confined spaces.

The Trumpf TruLaser Cell 3000 enables components to be joined precisely even without filler material. An adjustable processing lens allows the welding area to be precisely focused and positioned.
We develop and manufacture the necessary laser welding fixtures in-house, ensuring optimal component positioning as well as cost-effective and reliable process implementation.
Depending on the requirements, different welding programs and process strategies are used – ranging from spot and linear welds to dynamic welding movements (e.g., wobbling). If necessary, the process is carried out using the appropriate shielding gas to achieve the desired weld quality.

Laser marking. The TruMark 3000 fibre laser from TRUMPF is used for marking and applying logos, decorative patterns, information, or scales.
We offer a variety of solutions for your specific laser marking needs. For example, surface treatment of stainless steel for purely aesthetic purposes causes a change in colour – the surface remains smooth. Even when plastics undergo a colour change due to intentional dyeing or bleaching, the surface remains smooth. Laser texturing allows surfaces to be textured for functional purposes. Deep engraving with straight or angled edges is heat-resistant and can withstand mechanical stress. Paint stripping or layer removal is suitable for partially removing thin top layers from multi-layer plastics, or is also used, for example, to remove anodised coatings from aluminium.

Advantages of laser marking:

• durability
• it can be customised
• sequential numbering is possible
• cost-effective, e.g., no stencil costs compared to pad printing
• It can be implemented quickly

Custom laser engraving with your logo or decorative pattern.

Pressing, drawing, rolling

In our press and draw-forming division, we use hydraulic presses with capacities of up to 100 tons and a 10-ton draw-forming cushion to manufacture drawn parts, formed parts, and embossed parts, typically in small to medium quantities and involving multiple production runs.

Precision bending technology

Since March 2026, we have been using the Trumpf TruBend 7050 to bend the smallest to medium-sized parts for you with high productivity. This machine is a perfect fit for Windisch, because, just like us, it values precision. The maximum bending length is 1530 mm. But even small parts with complex edge details and bends with short legs are produced quickly and with precision. With a pressing force of 500 kN, material thicknesses ranging from 0.7 mm to 6 mm can be bent – depending on the geometry and material – without tooling costs, making it ideal for prototype production as well.

Resistance welding and projection welding

In the field of resistance welding, we assemble components – most of which we manufacture ourselves – into subassemblies and, when necessary, install and weld on weld nuts. If standard electrodes do not produce optimal results, we manufacture custom electrodes and special workpiece holders, welding fixtures, or tools in our tool manufacturing facility. For quality assurance purposes, three of our five resistance welding machines are currently equipped with process monitoring systems that monitor and record the parameters of each weld against a reference standard and interrupt the process in the event of a deviation. In addition to the test interval, the process reliability and quality of the welds are monitored and documented through tensile tests and pull-out tests.
The materials currently in widespread use are 1.4301, 1.4310, 1.4404, and tinplate. However, non-ferrous metals can also be processed using resistance welding under certain conditions, such as metal parts made of aluminium alloys with copper foil.

Small-series production

In our small-series Production department, we manufacture products for you using, for example,

• modern eccentric presses up to 55 tons
• hydraulic presses with a pressing force of up to 100 tons
• thread-cutting machines with lead spindle M2–M10
• small bench drills
• automatic thread-cutting machines
• hand-lever presses
• table presses
• and special-purpose machines

We process strips ranging from 0.10 to 3 mm in thickness, as well as strips cut from sheet material. We also manufacture punched parts here from materials such as plastics, rubber, perforated sheets, metal mesh and sealing felt.

Assembly of subassemblies

Individual parts are assembled into subassemblies according to your specifications, for example, through riveting, pressing, joining, and screwing, and then tested. A typical application is the press-fitting of press-fit threaded pins or press-fit nuts. Here, too, in addition to process-monitoring checks such as torque and extraction force, the press-in depth and press-in force are monitored and recorded as needed.

Wire bending parts

Windisch manufactures wire bending parts with a diameter of up to 2 millimetres. Manufacturability depends on the machine and the material and is assessed on a case-by-case basis.

Parts cleaning

Punched and formed parts, as well as assemblies, are cleaned and degreased in-house as needed using a PERO cleaning system with various cleaning cycles.
In addition, ultrasonic cleaning can be performed to remove any burrs or to more effectively clean blind holes and through-holes.
If necessary, the component is also cooled and cleaned using ionised air to remove loose particles and further stabilise the component’s surface.
When cleaning parts, it is possible to perform an inspection based on cleanliness classes/surface tension. In accordance with the requirements, the parts are handled with care after cleaning and then properly packaged.

Vibratory finishing/tumbling

To round off sharp edges and improve or modify the surface, we can treat the parts using vibratory finishing or tumbling, depending on the part geometry and material. Various grinding and polishing tools are available for this purpose. The parts are typically dried using corn in a vibrating dryer. The heated corn pellets absorb moisture, and at the same time, the parts are lightly polished.

Additional services

Windisch offers many other services, including semi-automatic surface brushing. Please send us an inquiry!
In collaboration with external partners, we provide coating services for raw materials and punched strips (partially or fully coated), as well as for frame and drum components (e.g., electroplated and chemical nickel plating, hard chrome plating, tin plating, silver plating, gold plating, KTL coating, pad printing, and insulating varnish), and

• pickling/chemical cleaning
• Anodizing
• Electropolishing
• Bainitic hardening of small mass-produced parts
• Vacuum hardening/tempering

In accordance with your shipping instructions, the parts will be carefully tested and packaged before shipment. Among other things, the following types of packaging and materials are used:

• disposable cardboard boxes
• Windisch reusable packaging
• packaging materials provided by the customer
• seaworthy packaging
• VCI bags/VCI chips
• ESD packaging
• plastic spools
• trays, insert boxes, compartments
• blister
• perforated mesh or perforated strip
• bulk material
• adjusted
• individual packaging
• and customised packaging solutions

We use external service providers for container management and cleaning services.

The problem – a case study: An urgent production order is due, but a tool failure occurs—for example, due to a miscut, a broken punch, or a crack in the cutting plate. Since the tool has already reached the end of its life cycle, neither replacement parts are available nor do digital drawings exist for quick reproduction.

Windisch has the solution: Using our Werth multi-sensor measuring device, we digitalise defective tool components such as punches or cutting plates and use the scanned data to create complete CAD files for CNC machining on milling and erosion machines. This made it possible to get even very old tools up and running again within a few hours using replacement parts. We are pleased to offer this service, as well as the digitalisation of components, on a contract basis.

Windisch is equipped with the necessary measuring instruments for sampling, incoming inspection, and in-process inspection. This means that, upon request, up to 100 percent of selected dimensions and properties can be inspected.

Keyence measurement technology has become an indispensable part of the production processes at Windisch. The IM-6025 digital measuring projector is used for in-process inspection. The IM-8030T digital measuring projector, equipped with a probe, light probe, and rotation unit, is used not only for in-process inspection but also for sampling.

The VR 5200 profilometer enables 3D measurement and surface roughness testing. The VL700 3D scanner scans real-world components, even complex ones, and measures their geometry with high precision. The data obtained in this way can be compared with the original CAD files, and finished CAD models can be created from the scanned data.

A universal testing machine can be used to test the mechanical properties of components, assemblies, materials, and welded joints through tensile and compression tests, in order to evaluate the results and document them in a traceable manner.

In addition, it is possible to determine the extraction force for press-fit components in order to verify the holding forces and validate process capability. The tests are carried out in accordance with the requirements for first article testing (FAI), in-process testing and quality assurance of ongoing production.

Our quality assurance system complies with the requirements of DIN EN ISO 9001:2015. In addition, upon customer request, we carry out initial sampling procedures and prepare the necessary documentation and analysis, such as flowcharts, FMEA, MSA, etc. For automotive products, we create IMDS entries in the database.
In addition, we fulfill extensive compliance requirements, such as CMRT/EMRT material declarations or declarations regarding specific ingredients, in accordance with various customer specifications and regulations, including REACH, SVHC, POPs, and RoHS.
After inspection, materials are stored according to the FIFO principle.
Windisch uses the ERP system “Sage 100” to manage orders from order receipt through production to the preparation of shipping documents and invoicing. The inventory management system is continuously being developed and improved. The EDI interface enables flexible data exchange with various customer portals, such as JAGGAER.
urthermore, various delivery models tailored to the customer’s needs can be implemented to ensure a supply that is both efficient and tailored to their requirements.
As part of ongoing digitalisation efforts, we currently plan to implement the EMC MES software for production control – smart manufacturing – in certain areas of production in order to manage manufacturing processes transparently and monitor them in real time.

Windisch has taken its social responsibility very seriously for generations. For example, company founder Max Windisch donated a new set of bells to the church at the company’s location in Zwota in 1946 and to the neighbouring parish of Erlbach in 1947.
Windisch‘s current involvement is wide-ranging and begins right within the company. Our relationship with employees of various nationalities is characterised by openness, fairness, the creation of career opportunities, and the promotion of team spirit.
At the company‘s location, kindergartens, schools, and clubs, among others, receive financial support. Windisch also supports international aid organisations such as “Doctors Without Borders” and “Save the Children”.
When it comes to environmental protection, resource conservation, and sustainability, Windisch goes far beyond the standards required by law. For example, the company generates ten percent of its energy needs itself through its solar power system.

Windisch has built its business around its traditional core competency – tool manufacturing – and has continuously expanded its operations. The precision punching, resistance welding, and laser processing departments, as well as the small-series production division, work closely with the design and tool manufacturing departments to develop optimal solutions. Short routes, flat hierarchies, in-depth expertise, and years of experience ensure high efficiency and the best quality.

Tool manufacturing and Prototypes: 4 Employees
Precision automatic punching machines: 3 Employees
Small-series production: 4 Employees
Resistance welding/Laser processing: 3 Employees
Administration/Office staff/Logistics:

• Inquiry processing
• Tool Design
• Order processing/procurement (2 Empoyees)
• Work preparation
• Process specialist/QM Assurance
• Repair
• Training
• Human Resources/Accounting
• Warehouse, shipping, final inspection (2)