Kevin (left) and Marcel Kempf, put entrepreneurial courage before pure cost calculation. Photos: TrumpfBy investing in a TruLaser Weld 5000 laser welding cell from
Trumpf, brothers Kevin and Marcel Kempf took an entrepreneurial risk as they only had a few parts optimised for the new process. With a clever idea, their employees were motivated to change this in a short space of time, and the results were so good that many customers now only want laser-welded parts.
Kevin and Marcel are passionate about sheet metal processing. Trying out new technologies and processes to further the development of their company is what drives their enthusiasm and takes a fair bit of courage to boot. Kevin said: “If we only ever took the bare cost calculations as the basis for our decisions, we wouldn't have been able to consider some of the machines we have purchased in recent years. But we like looking at the bigger picture. We cannot offer our customers technologies which we do not have the machines for — so that means we are missing out on business. That is why we sometimes take a risk.”
As was certainly the case with the decision to invest in an automated laser welding cell from Trumpf. The technology had long fascinated the brothers, and when the TruLaser Weld 5000 with the FusionLine option came onto the market, their interest hotted up.
In addition to laser tube processing with the TruLaser Tube 5000, Kevin and Marcel Kempf now also have automated laser welding in their portfolio. With the help of the TruLaser Weld 5000, they were able to expand their customer base even furtherThe FusionLine option makes it possible to compensate for inaccuracies in a component and thus automatically process components that are not optimised for laser welding. Gaps up to 1mm wide can be closed easily without compromising the quality and strength of the weld seam. Marcel said: “That was what convinced us — we ordered the system in 2018.”
Andreas Kempf founded
Kempf GmbH in 1987 and in 2020, his sons Kevin and Marcel took over management of the family business. With its headquarters in Kraichtal-Gochsheim, Baden-Württemberg, it is a contract manufacturer for sheet metal and tube technology and supplies around 500 customers in a variety of industrial sectors including machine and systems engineering, fixture construction, medical and rehabilitation technology as well as the automotive and electrical. With around 70 staff, the company covers the entire sheet metal process chain - from component design to surface refinement.
Taking the plungeThe brothers invested in the expansion of the welding shop back in 2017. In addition to the standard TIG, MIG and MAG welding processes, it was now time to take the plunge into automated laser welding. Kevin explained: “Everything fell into place in one fell swoop. With FusionLine, Trumpf has lowered the previously extremely high demands on component accuracy in preparation for laser welding. Furthermore, it is no longer necessary to invest heavily in milled fixtures. The shortage of skilled workers, which is also a problem for us, has made it clear how important automated production processes are. The issue has become even more acute since the Covid-19 pandemic.”
When commissioning the TruLaser Weld 5000, the Kempf brothers initially encountered the same problem that still prevents many sheet metal fabricators from purchasing laser welding systems; they were not producing the right parts to benefit, plus the prospect of a new process is often rejected by customers. Explaining the dilemma, Marcel said: “Many people think only a thick seam can be stable. Although we have destroyed components and proven that it is the material rather than the delicate laser weld seam that tears, although this evidence is often not enough to convince people.”
The Kempf employees were also initially not too keen on redesigning components for laser welding and building the devices required for the welding process. Kevin continued: “That's when we came up with the idea of offering a bonus for every laser-weld-optimised part. This piqued the interest of our ambitious employees.”
Marcel Kempf (left) is delighted with the quality of the laser weld seams, and so are his customersThe specifications were simple — they had to present a processing program, the appropriate fixture and a short video or photo documentation of the new process. Of course, they also needed to be able to win over customers with their idea. Kevin added: “The work was worthwhile for both sides, and for the employees, their ideas paid off in hard cash. We have also profited — 80% to 90% of our parts are now optimised for laser welding."
Together with their sales team, the Kempf brothers have now also won over their customers. Kevin explained: “When I showed a customer three laser-welded samples and he ended the meeting after what felt like 5min, I was shocked and perplexed. Until the customer got in touch shortly afterwards and said that he had never seen such great samples before and that he would be sending an order!”
Marcel added: “This customer is one of our biggest today. Without laser welding, we wouldn't be able to achieve the turnover we make with it.”
The speed, quality and, above all, the reproducible results continue to inspire Kevin and Marcel Kempf. Kevin said: “We have components that took us over an hour with TIG welding and the necessary post-processing — we can do it in 10min with laser welding. We can do in one shift what used to take us a whole week.”
Another decisive factor for the brothers is that the TruLaser Weld 5000 not only processes the orders quickly and punctually: it also delivers 100% reproducible welding results at all times. The Kempf brothers have not regretted moving into automated laser welding, especially as they have not only managed to attract new customers, but also convincing existing customers to make the switch. Kevin concluded: “Once you have seen a laser welded seam, you won't want anything else.”