Inside Wiegel: A Deep Dive into High-Precision Metal Stamping and Automation

At Munro & Associates, we don’t just review final products—we trace innovation to its roots. In this behind-the-scenes facility tour, Sandy Munro walks through the expansive operations of Wiegel, a third-generation, family-run manufacturer evolving at the cutting edge of high precision metal stamping and automation. This deep dive reveals how Wiegel’s investments in servo presses, robotic automation, and proprietary welding solutions are reshaping the production of EV components like busbars, terminals, and current collectors.

From its tool-and-die roots to its current full-system integration, Wiegel’s evolution clearly reflects the broader manufacturing sector’s push for speed, precision, and scalability. Over time, this transformation has been driven by the need to stay competitive and responsive to customer demands. As a result, their focus today is centered on providing OEMs and tier suppliers with next-gen parts—delivered through lean design principles, advanced automation, and relentless innovation.

From Legacy to Lean Innovation

Wiegel’s story began in 1941 as a tool-and-die shop. Today, under Aaron Wiegel’s leadership, the company has expanded beyond stamping to become a vertically integrated manufacturing hub. They’ve phased out their original “Tool Works” branding to reflect their wider capabilities—now encompassing automated welding, assembly, molding, and wire EDM operations. The company employs over 50 robots and has launched operations in Mexico to support growing demand.

Their approach is customer-centric: build what’s needed in-house, or source it smartly until it makes sense to internalize. This philosophy has made Wiegel a one-stop solution provider for precision metal components, particularly in the rapidly scaling EV sector.

Patented Welding and Busbar Production

The facility’s crown jewel? A custom-built, patented welding system for aluminum busbars—only four such machines exist in the U.S. Developed in collaboration with two domestic partners, this line joins 80,000-stick aluminum busbars to 5,000-stick aluminum foil through precision fixturing, robotic feed systems, and roller compression. The process produces complex, layered electrical components essential to EV battery packs.

By using Fanuc robots, vision systems, and revolving fixtures, the system efficiently handles multiple configurations across varying production needs. Significantly, it maintains high throughput and precision. Which, in truth, means performing with minimal human intervention, thereby highlighting Wiegel’s strong commitment to automation and long-term repeatability.

Assembly Through Automation

Once components are welded, they enter a fully automated assembly line that includes Komatsu presses and carousel-style fixturing. This line supports transfer die operations (in contrast to progressive dies), allowing loose-piece stamping and robot-assisted part movement.

Key stations include:

Vision-inspected robotic feeding of stamped busbars.
Application of aluminum foil and UV-cured gluing of plastic frames.
Placement of flex circuit boards with vision alignment and air bubble elimination via rollers.
Laser welding of nickel ribbon connectors linking circuit boards to busbars.

Each part receives a unique QR code—encoding revision level, date of manufacture, and serial number—scanned by OEMs for traceability and quality control.

Presses, Dies, and Material Strategy

Wiegel’s press lineup includes everything from high-speed Bruderer machines, capable of running up to 1,500 strokes per minute, to heavyweight Minster presses topping 450 tons. As a result, this extensive range allows them to handle a wide spectrum of parts. Specifically, they can stamp everything from ultra-thin foil terminals to thick copper and aluminum busbars.

They use:

Servo presses for complex draw work.
Precision straighteners (some with 13 to 19 rollers) to flatten and destress materials.
Progressive and transfer dies to reduce changeover times and increase throughput.

Stamping materials range from tin-plated copper to silver-plated alloys. As Aaron Wiegel notes, material cost can account for up to 80% of production cost—especially with copper. Minimizing scrap through die optimization and effective layout design is thus a priority.

Quality Control at 68 Degrees

Wiegel’s climate-controlled quality lab is held at a consistent 68°F for dimensional stability. Here, operators use:

CMMs (Coordinate Measuring Machines)
OGPs and Keyence vision systems
Profilometers, Rockwell hardness testers, and cleanliness (Millipore) checks

All data is uploaded in real time and made available to customers. Inspection spans first-piece, in-process, and final-part checks, guided by the company’s PPAP (Production Part Approval Process) protocols.

Die-Making and EDM Precision

The tool and die department showcases state-of-the-art wire EDM (Electrical Discharge Machining). This process cuts intricate profiles in hardened steel blocks with tolerances in the millionths of an inch. Operators like Wayne Protoski, a 45-year veteran, ensure the accuracy and performance of punches, die blocks, strippers, and inserts.

Advanced 4-axis wire EDM machines allow different geometries at the top and bottom of a punch—crucial for mold dies or specialized tapers. Wiegel also uses a rare CNC optical profile grinder (common in Germany and Japan) to produce stress-relieving punch geometries, reducing breakage in high-load applications.

CNC Centers: Horizontal vs Vertical

The facility includes both vertical and horizontal Okuma machining centers. While vertical centers are more common, horizontal models reduce downtime by staging tombstones offline—letting operators cut chips almost continuously.

This strategy aligns with Wiegel’s mantra: eliminate variables wherever possible. Whether through brand loyalty (Minster, Komatsu, Okuma) or environment-controlled machining rooms, consistency underpins every investment.

Takeaways for Engineers and EV Innovators

Wiegel offers more than parts—they deliver insight into what scalable, high-precision, lean manufacturing looks like today. For automotive engineers, procurement leads, or EV system designers, this tour demonstrates:

How proprietary welding systems can revolutionize busbar assembly.
Why servo stamping and robot-fed dies enable design flexibility at high volumes.
How vision systems and 100% in-line inspections support quality in mission-critical EV components.

Their facility design, automation integration, and material flow optimization represent the convergence of legacy know-how with modern engineering demands.

Ready to Elevate Your EV Manufacturing?

If you’re developing next-gen EV components and need a partner who understands lean design, complex tooling, and automated precision, Munro encourages you to explore what Wiegel has to offer. Their ability to adapt, automate, and scale makes them a valuable link in the EV supply chain.

Check out to Munro & Associates for more teardowns, insights, and to find out how companies like Wiegel fit into a smarter, leaner, electrified future.