production /

manufacturing methods

We like to break new ground and develop innovative products together with our customers and partners.

 

The realization of our products is done by our own designers and developers with the help of the latest CAD/CAM techniques. Punching and bending tools as well as injection molding tools and special machines are manufactured in our own company network.

 

zella-mehlis

Here is the birthplace of our company. Founded in 1920, tuning forks and toolboxes were initially produced here, which were supplemented just a few years later by bicycle parts such as pedals and hubs. Today, bicycle lighting and reflectors are produced here, as well as decorative nuts individually tailored to the customer. The high-quality Wittkop leather saddles are also handmade here.

Decorative nut production

Wittkop saddle production

Ultrasonic welding of reflectors

oederan

The production of the rims and wheels as well as high-quality aluminum mudguards in Oederan is carried out at the highest technical level with specially developed machines that enable customizable production. In this process, the manufacturing methods are designed according to our own ideas and customer requirements. These technologies are protected by numerous patents and utility models. This is also the home of the VUELTA Germany and EXAL brands.

Rim production

Wheel production

Mudguard production

barchfeld I

At HMM Kunststofftechnik GmbH & Co KG, thermoplastic polymers are processed on horizontal injection molding machines. The articles meet the highest qualitative requirements, also in the automotive industry (certified according to TS 16949). Products of GEKA Lichttechnik GmbH are also produced here.

 

The Barchfeld logistics center has more than 4000 pallet slots.

Plastic injection molding

Production of warning triangles

Logistics Center

barchfeld II

BÜCHEL INDUSTRIE GmbH & Co. KG is our newest production facility, which was put into operation in 2019. Spokes and nipples are manufactured here on fully automatic high-performance press-bending machines and automatic milling machines. The machines for the production of the steel mudguards were developed in-house.

Shaping of mudguards

Spoke production

Nipple full automatic machine

rothenburg

Kuhnert® products are manufactured on state-of-the-art fully automatic bending machines and specially designed automatic welding machines. Technical processes such as Mig/Mag gas-shielded welding, machining with resistance welding machines and the CNC bending center for tubes ensure the highest quality with the largest possible production volume.

Bending machine

Detail of a CNC bending machine

CNC Tube Bending Robot

eislingen

GEKA Lichttechnik GmbH & Co. KG was founded in 1952 and has been one of the leading, globally active companies in the field of vehicle safety for decades. Since 2016, GEKA has been part of the Büchel group of companies under new management.

Film plotter

Laminate foil on board

Light mounted on panel

jiashan, china

Our joint venture, U-Star Electronics Technology Co., Ltd., manufactures high-performance and energy-saving LED lighting using the latest technologies.

View into the fully automated pre-assembly

Assembling the circuit boards

Lighting final assembly

ludhiana, indien

Citizen-Buechel Biketech, the Indian joint venture founded in 2017, manufactures reflectors according to ISO in compliance with the latest legal requirements, primarily for the Indian market.

Injection molding

Ultrasonic welding

Quality control

research /

development

In order to guarantee that our customers’ wishes are processed as individually as possible, we are constantly fine-tuning our processes and production methods. Our products and machines are realized according to our customers’ suggestions and our own ideas. The implementation of new product ideas, taking into account customer requirements, is carried out by our designers and technicians with the aid of the latest CAD/CAM techniques. Necessary tools and equipment are developed and manufactured in our own group of companies.

 

Büchel Felgenproduktion and Vuelta Deutschland GmbH, for example, have been developing machines for the technical implementation of their own ideas in cooperation with the Steinbeis Transfer Center at Chemnitz Technical University since 2002. These include lathes that enable the simultaneous machining of the two braking surfaces of a rim, or a dynamometer that accurately maps track protocols for testing wheels.

 

Our intelligent brake indicator function STOPTECH is a joint development with the Fraunhofer Institute in Dresden. This function works sensor-controlled, without additional cables.

 

We also hold a large number of patents and utility and design patents, more than 100 in total. Together with 3M, a reflex rim has been developed to production readiness that meets all international lighting standards, as well as the worldwide patented reflex spoke and the Sekuclip spoke reflectors.

Double-sided turning of the braking surface, developed in cooperation with the University of Dresden

Angular punching on self-developed punching machine

Millimeter precision inspection of the finished parts

Setting up a CNC injection molding machine at HMM

Fully automatic application of the reflective strip to the patented reflective rim, developed with University of Chemnitz

quality management /

highest standards

Our production facilities are certified according to DIN/EN and ISO. Permanent quality monitoring takes place in our own test laboratories, from material testing and mechanical stress to aging tests and photometric light tests.

 

For example, in cooperation with the Steinbeis Transfer Center at Chemnitz University of Technology, we have developed a testing machine that is used to perform digitally simulated load tests to test the effect of forces on wheel profiles. With the products of HMM Kunststofftechnik we meet the requirements of the automotive industry (e.g. VW Group) as an A-supplier and are certified according to DIN ISO TS 16949.

 

We maintain our own office in Shanghai, which is responsible for ensuring quality standards in the Chinese productions of our joint ventures. In addition to monitoring quality standards, this also includes checking compliance with the Social Code of Conduct, BSCI, which prohibits child labor, forced labor and unfair pay, for example, and verifies compliance with regulations on worker protection.

 

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