Our areas of expertise
Our areas of expertise complement one another seamlessly, providing targeted expertise at every stage. This results in a coordinated development process characterised by clear structures, efficient workflows and a high degree of reliability in implementation.
Close collaboration across all departments ensures short decision-making processes and consistent quality throughout the entire process. This enables us to respond flexibly to requirements and efficiently bring solutions to series production.
We take care of the entire product development process for our customers—from the concept phase through sample construction, prototyping, and validation to series production.
We combine design, simulation, and manufacturing expertise to develop safety-related components efficiently, reliably, and to a high technical standard. We work with Catia V5 and LS-Dyna.
We perform CAE-based validation of components, systems, and complete vehicles. This includes static and dynamic structural, crash, and safety calculations, stiffness, strength, and abuse analyses, CFRP simulations, pyrotechnic processes, and ballistic loads, as well as the creation of material maps and simulation models. We use LS-DYNA, Medina, Ansa, and Animator for this purpose.
We perform the most important manufacturing steps in-house—from mechanical processing and welding to assembly. Our mechanical processing is characterized by the precise manufacture of components and assemblies in accordance with the highest quality and safety requirements. Our welding processes are characterized by a high degree of automation – reliable, reproducible, and quality-tested. During assembly, the components are assembled into functional assemblies and systems.
Innosafes offers extensive testing facilities for testing components and systems under realistic conditions. These include environmental testing, pressure and tensile testing, and functional testing, which are used both during development and for quality assurance purposes.
Environmental testing
We conduct corrosion tests and climate and climate change tests to simulate real environmental and stress conditions. Our environmental simulation and climate change test chambers can simulate temperature ranges from –40 °C to +180 °C and humidity ranges from 10 to 98 % relative humidity. The high temperature change rates enable standard-compliant material and component testing under dynamic conditions and provide reliable information on durability and service life.
Compression and tensile testing
We perform strength tests in accordance with customer-specific specifications on our specially developed compression and tensile testing machines. Forces of up to approx. 200 kN can be achieved at a pressure of up to 180 bar. In addition, a compact testing system is available for smaller and quick tests, which is used, among other things, for incoming goods inspections.
Functional tests
For functional tests, we have specially developed release devices that can be used to test rollover protection systems specifically for their function and reliability. This enables us to ensure that the systems work perfectly under realistic conditions. We also use high-speed recordings for detailed investigations.
Innosafe’s prototype workshop produces functional prototypes for development and pre-series projects. Thanks to experienced specialists and close links to development, testing, and production, prototypes can be implemented quickly and validated in a practical environment.
We use modern and powerful measurement technology to ensure the quality of our manufacturing. A key element of this is the GOM ATOS III from Zeiss.
It enables non-destructive 3D digitization and the inspection of component surfaces and dimensions at various points in the manufacturing process. Measurements are taken at various points, including during goods receipt, after welding processes for plant setup, and as part of initial and final inspections.
With a measuring field of 700 mm, the scan data recorded by the ATOS III is compared with the corresponding 3D CAD data and evaluated in Zeiss’ INSPECT software. The results are then available in the form of detailed test and measurement reports.
The GOM ATOS III offers the following options:
- Complete 3D scanning and 3D digitization of components
- Generation of precise 3D mesh data as well as comparison and processing in all common data formats
- Comprehensive inspection software with detailed logging
- Wide range of evaluation options for development, quality assurance, and production monitoring. In addition to optical measurement technology, we also carry out micrographic examinations. We check the welding quality in our laboratory. With the help of our LEICA microscope, microstructures, weld seams, and material transitions can be analyzed and evaluated in detail.
