trendgineering
In the fast lane with a luxury car
| Petra Rehmet
How Osbra is defying the automotive crisis – with support from KraussMaffei
It’s seen action in desert rallies, served as the Popemobile, and operates in crisis zones: the Mercedes G-Class. Since 1979, this rugged off-roader has also found fame among Hollywood stars and sheikhs, especially in its sleek AMG version. Key exterior parts like bumpers, fender flares, and more come from Osbra GmbH, which supplies OEMs with both injection molding and reaction processing – using systems from KraussMaffei. And the next production expansion is already on the horizon.
When does injection molding make economic sense, and when is it better to use parts made of polyurethane (PU)? This is a question Siegfried Richter, CEO of Osbra, faces daily – and one he can answer from both sides, since Osbra offers both technologies.
Aside from geometry and intended use, production volume is a key factor. With around 40,000 G-Class vehicles produced annually, the higher upfront investment in injection molding is easily justified.
But what about a brand like Aston Martin, with only around 2,000 units of its “volume model,” the DBX? Here, a higher part price for PU may be acceptable, due to longer cycle times and more manual post-processing.
However, the tooling costs for PU are significantly lower. Often, it makes sense to manufacture large parts or components with significant wall thickness variations in PU, while smaller attachments are more efficient in injection molding – allowing both technologies to be used where they shine most.
Sustainable growth
Richter has observed a surprising trend: young engineers are rarely trained in PU processing anymore, making Osbra’s know-how all the more valuable.
Based in Bad Wörishofen, the company has become a top-tier supplier for premium car manufacturers, offering flexible materials and delivering complete assemblies straight to the production line.
This positions Osbra in an exciting niche, where it continues to grow sustainably, despite industry headwinds. Founded in 1981 as a toolmaking shop, Osbra first established itself in PU processing, then entered injection molding in 2017.
We had such great experiences with the PU systems that we chose KraussMaffei for our injection molding machines as well. The proximity made collaboration easy, and we’ve been very satisfied with both service and support.Siegfried Richter
Managing Director Osbra GmbH
In 2023, Osbra opened a new, ultra-modern facility spanning 16,400 square meters, housing five injection molding machines ranging from a fully electric PX (1,600 kN) to a MX model with 14,500 kN clamping force. In addition, there are 13 mold carriers (up to 5,000 kN, part weights up to 12 kg).
These machines serve customers like Mercedes-AMG, Porsche, BMW Alpina, Aston Martin, and Maybach, offering a deep level of vertical integration that includes development, prototyping, tooling, production, and even post-production testing.
A look at production: With injection molding machines from KraussMaffei in the clamping force range from 1,600 to 14,500 kN, Osbra offers renowned customers such as Mercedes-AMG, Porsche, BMW, Aston Martin and Maybach a large vertical range of manufacture.
Premium bumpers for the G-Class
One example is the fully painted bumper for the G-Class (2.8 kg shot weight, polypropylene), which integrates PDC (Park Distance Control) sensors. The grille features two cover components and chrome accents, hot-stamped in three color variants.
Each complete assembly – including electronics and wiring – leaves Osbra as a ZB component, ready for direct vehicle installation.
From bumpers to headliners: Osbra produces and finishes a wide variety of components for exterior and interior applications.
Elegant exterior and interior
In addition to bumpers and grilles, Osbra supplies rear and front spoilers, fender flares, and side skirts. Inside the vehicle, the company applies its finishing expertise to elements like center consoles and headliners, working even with fabrics and carpets.
With around 400 employees across four locations, Osbra generates over €80 million in annual revenue.
With premium vehicle series, the goal is always to push the luxury factor even further – even if it comes at a cost. For example, the AMG G-Class, which Osbra has supported for over 30 years, has been available in 44 standard colors.
Now, it can even be customized in tie-inspired color tones – meaning lot size 1 in paint application for Osbra.
Luxury in color: The Mercedes G-Class in orange - a statement on four wheels, refined with Osbra components for the exterior and interior.
At Magna Steyr in Graz, the G-Class manufacturer accepts lead times of two years or more for such custom orders and maintains a strict sales policy.
One exception: Richter recalls a sheikh who ordered 50 G-Classes for his 50th birthday, gifting 49 to family and keeping one for himself – at €250,000 each.
Top equipment for top quality
Naturally, those who deliver high-end quality also demand the best equipment. Osbra’s five KraussMaffei machines are outfitted to a premium standard, including magnetic clamping plates that significantly reduce tool change times.
One fully electric PX 161 has widened platens, and one MX 1,300 is equipped with a high-wear-resistant screw.
All machines utilize LRX linear robots and the full socialProduction package from KraussMaffei – offering digital tools for production, process, and service control.
productionMonitor gives a fast overview of machine status and efficiency, while processSupport continuously analyzes operations with a self-learning algorithm. liveCare monitors wear conditions and supports predictive maintenance.
Well-established team from Osbra and KraussMaffei: Florian Eilhardt, Raphael Mangold, Wolfgang Rössler, Siegfried Richter, Ralf Böhm, Martin Miezek, Halil Ibrahim Altinkaya, Benjamin Miller and Stefan Betzing (from left)
Optional gas injection and chemical foaming
Injection molding using gas injection is just as possible as chemical foaming. The APCplus machine function adjusts the switchover point from shot to shot based on the melt viscosity and ensures consistent component weight right from the start.
This is particularly advantageous for frequent mold changes, as is often the case with small series.
The new factory building is future-oriented with its roof-filling photovoltaic system, which covers up to 100 percent of the company's own requirements. There is underfloor heating in the offices and production area, which can also be used for cooling in summer.
Together with high-quality insulation, heat recovery and heat pumps, Osbra achieves energy savings of 60% compared to similar conventional industrial buildings.
G-Class as an electric version
Osbra is as innovative as its production plant when it comes to new projects. Since 2024, the G-Class has been available to order as an all-electric vehicle for the first time.
In terms of appearance alone, this version should stand out from the previous ones. In addition to a newly designed LED-illuminated radiator grille, a two-part storage box was also created, which is located on the rear door where the spare wheel used to be.
The charging cable is conveniently stowed in the box, which the driver can lock and unlock from the seat. The electronic components installed mean that the box had to be absolutely rainproof and pass the usual climate change tests without distortion.
The development proved to be challenging, but it was a successful team effort between Mercedes and Osbra.
In a two-tone design: The smart storage box of the all-electric Mercedes G-Class securely holds the charging cable and, thanks to integrated electronics, is both rainproof and climate-resistant.
Further exciting projects are already being planned. For one of them, it will be necessary to expand the production facility in Bad Wörishofen to include an additional hall with a large mold carrier and two polyurethane systems.
Osbra has already purchased the land for this: "And we already have the offer from KraussMaffei in house."
