KraussMaffei has unveiled the BrightStar electric press, a fully electric platform designed for automated press lamination and edge folding in the production of lightweight and soft-touch components for the automotive industry. Developed for high repeatability and process control, the system combines a new electric drive with an innovative heating package that provides precise temperature regulation for heat-based adhesives. Beyond its primary scope, the platform can also be configured for combo punch and ultrasonic welding tasks, expanding its application window.
The BrightStar incorporates an integrated Quick Tool Change option to accelerate and simplify setup while improving operator safety. New safety features embedded in the main tool sequence program protect tooling against damage, and users can perform selected changes to the tool program themselves. These capabilities enable immediate, on-site process adjustments without the need for a service technician, which shortens response times and increases production flexibility.
"With BrightStar, we are demonstrating that we listen to our customers," said Dr. Frank Szimmat, Managing Director of KraussMaffei Technologies GmbH. "The demands for lightweight construction and efficiency in the automotive industry are constantly increasing; with this new generation of presses, we offer a solution that is both more productive and more user-friendly."
Variants and process scope
The BrightStar electric press is offered in three variants with 5, 10 and 20 tons of pressing force. The platform is fully modular and can be customized to customer-specific processes and automation concepts. A high-precision mold set integrated in the upper plate area eliminates the need for additional tool guidance, which is a key benefit for process reliability and repeatability.
The model supports a broad range of processing options, including:
- press lamination
- edge folding
- sonic welding
- IR welding
- light punching
- skin trimming
BrightStar Lite and lifecycle expertise
Complementing the main platform, KraussMaffei offers the BrightStar Lite as a cost-effective option for low-tonnage applications. Available in a 5-ton version, the Lite variant features an expanded mold space, enlarged from 1,700 mm to 2,500 mm. Design optimizations reduce overall weight while maintaining the same stability and precision as the regular BrightStar configuration.
According to the company, the development of BrightStar and BrightStar Lite incorporates the team’s experience from all phases of the tool lifecycle, from concept and design through manufacturing to commissioning. This knowledge base is reflected in the platform’s emphasis on precise thermal control, modular configuration and protective safety routines that target consistent, repeatable operation.
