Consydera is one of the largest metal and sheet metal processing groups in Europe, composed of four complementary companies: Aussafer Due srl, Laserjet Spa, RAMO srl (all based in Italy), and Hailtec GmbH (Germany). With a consolidated revenue of over 100 million euros, more than 500 employees and five production plants across Europe, the group operates with a uniquely broad and integrated technological portfolio: over 35 laser cutting systems and more than 150 machines; over 50 manufacturing technologies, and the capacity to handle both micro components and 14-meter-long structures, with high precision and speed. Its Consydera Electric Division brings together the technological and application expertise of Aussafer and Hailtec, focusing on advanced components for electrification.
Expertise in prototypes of stators, rotors and busbars for next-generation motors
The division develops and produces high precision laser-cut stator and rotor laminations and stacks, busbars, cell connectors, and custom components for many markets, like e-mobility, renewable sources (wind and hydro), nuclear, aerospace, and defence. With a strong focus on prototyping, small series production, and high-mix applications, Consydera Electric leverages technologies such as high precision laser cutting (-/+ 5 microns), stacking, laser welding, ultrashort-pulse laser micromachining, micro waterjet, CNC machining. Looking ahead, the division continues to invest in process automation and digitalization, and in a sustainable production, with the aim to become the reference development partner for electrified systems across Europe and internationally.
Challenges and opportunities
Aussafer’s and Hailtec’s CEOs Giacomo Citossi and Alexander Renz do not deny the electric transition is still far from being completed and left many expectations, so far, unmet. Nonetheless they are confident that, once some obstacles and criticalities are removed, future might seem much brighter. «This is not just a matter of if», they stated, «but also when and how much. The transition to electric mobility is clearly slowing down in some segments, particularly in the passenger vehicle market, where adoption has fallen short of institutional and OEM expectations. There are still several critical challenges to overcome. In first place, the – limited – battery range and charging times are not yet fully aligned with users’ expectations. Then, the lack of a widespread, reliable charging infrastructure is creating uncertainty and slowing confidence. Last but not least, the high cost of energy in many European countries is making EVs less attractive compared to traditional options».
That said, Citossi and Renz’s opinion is that «electrification remains an irreversible and long-term trend, not only in the automotive sector, but also in industrial, energy, aviation, and rail applications». In fact, the market is evolving and asking for lighter, more efficient electric motors, and innovation is therefore accelerating. «At Consydera Electric, we are deeply involved in this transformation: we’re actively developing and supplying prototypes of stators, rotors, and busbars for next-generation motors, supporting customers from R&D to industrialization as an agile, strategic partner», they said.
Ambitious goals
Despite the controversial scenario, Consydera Electric plans to more than double its sales over the next five years. «The potential is enormous», Giacomo Citossi and Alexander Renz observed, «and there’s a real momentum in the development of e-motors across multiple sectors: and we are right at the heart of it. Our company gathers the strengths of Aussafer and Hailtec and their combined expertise allows us to express a unique value proposition in terms of know-how, R&D and precision capabilities, with deep synergies across teams and technologies. The European market remains our core, thanks to the strong demand in the DACH region, Northern Italy, and France, where many OEMs are striving to develop electric motors without depending on extra-European supply chains». Consydera’s setup – with Aussafer Laminations in Italy and Hailtec in Germany – gives the group a pan-European footprint and perspective, providing it with the flexibility and ability to scale quickly.
«We’re also seeing growing opportunities in Eastern Europe and North America. In June», the two CEOs anticipated, «we will be exhibiting for the first time at Coiltech USA, a key step for expanding our presence in the American market where our competences can support local companies in developing new-generation electric motors. Our diversification is also a point of strength: in addition to automotive, we work in the aerospace, medical, defence, racing, and energy sectors. This gives us resilience and insight into cross-sector trends, and we’re ready to scale up wherever innovation and electrification are happening. We are actively developing new technologies and solutions under the Consydera Electric brand, in such fields as high-density motors and high-efficiency laminations».
Versatility first
Consydera Electric delivers a full-service offer ranging from technical consultancy and component design to prototype manufacturing and pre-series production, on top of laser-cut lamination. The starting point is represented by high-precision laser cutting capabilities with a -/+ 5 microns tolerance, ensured by internally developed and custom-built machines, otherwise unavailable on the open market. This is what allows the company to select the right process for each project, instead of adopting a one size fits all approach: a competitive advantage, according to Renz and Citossi, especially when it comes to R&D-driven contexts where performance is the top priority. Furthermore, given a 40,000 tons yearly output, the group believes its supply chain can prove absolutely reliable and competitive and at the same time that its manufacturing model can display sustainable and resource-efficient. As for the Italian market and the relevant supply chain, heavily impacted by the stop & gos on the path towards electrification, Consydera’s views are reasonably optimistic.
«Italy», Citossi and Benz considered, «has a long-standing tradition of industrial excellence, and we see a growing potential, especially in the development of powertrain components for EVs, industrial motors, and e-mobility applications. We’re exploring opportunities of collaboration with R&D teams of OEMs, Tier 1 and Tier 2 suppliers, technology startups, universities, and testing centres. To be a part of the Italian industrial ecosystem gives us access to innovation, engineering talent, and a strong manufacturing network, and the chance to boost our competitiveness in terms of speed and cost. At the same time, as an Italo-German group, we benefit from being deeply rooted in Germany’s Electric Motor Valley, one of the most advanced hubs for electric motor research and innovation worldwide. This dual identity gives us a unique position: deep industrial roots, cross-border development capabilities; and access to the most important European industrial ecosystems».
More than just quality
At Consydera Electric, EVs are just a piece of a wider puzzle, since the company is specialised in industrial automation, renewable energies, aerospace, racing, medical, defence, railway, nuclear, energy and power generation, oil & gas, and many others. And its product portfolio reflects the vast variety of its skills: from ultra-thin laminations (50 microns) to thick ones (up to 6 millimetres) for large generators. «This ability to deliver top-tier performance across such different applications is what really defines our added value. We’re proud to say that we’ve earned a very high level of customer satisfaction in all the markets we serve—not just for the technical quality, but also for our responsiveness, speed, and ability to adapt to complex requirements», the two managers reported. «We have a CAPEX plan», they added, «of several millions already in motion, aimed at expanding both our technological capabilities and our geographical footprint. More than just on technology, we are also working on the strategic growth of the group: new partners and companies will join Consydera, opening the door to new markets, new competencies, and new facilities. These investments are essential to stay ahead of the curve and keep delivering the innovation, speed, and precision our customers expect from us. At the same time, we are actively looking for new partners who share our vision and ambition and want to grow with us and shape the future of electrification».
